Slidable boring tool with fine adustment

ABSTRACT

Methods and apparatus for fine adjustment of the position of the cutting tool. In one embodiment, a boring tool includes a coupling member driven by a CNC boring machine, a cutting tool which is slidably coupled to the coupling member, and a slidable adjustment member. A frictional force resists sliding movement of the cutting tool. The frictional force is sufficient to retain the position of the cutting tool during machining operations. However, the frictional force is insufficient to resist an adjusting force applied by the adjustment member. Sliding motion of the adjustment, either by pulling or pushing it, results in movement of the cutting tool. In one embodiment, the cutting tool and the adjustment member are slidable in different directions. In another embodiment, the boring tool is adapted and configured to convert a first, greater amount of movement by the adjustment member to a second, lesser amount of movement by the cutting tool.

This application claims the benefit of priority to U.S. Provisionalpatent application No. 60/375,320, filed Apr. 25, 2002. This applicationis a continuation-in-part of and claims priority to U.S. patentapplication Ser. No. 10/023,243 filed Dec. 18, 2001. That applicationclaims the benefit of priority to U.S. Provisional Application Ser. No.60/256,371, filed Dec. 18, 2000; and Ser. No. 60/270,723, filed Feb. 22,2001. All of these patent applications are incorporated herein byreference.

FIELD OF THE INVENTION

This invention concerns an apparatus for a tool used when performing amachining operation, and more specifically to a boring tool used with aComputer Numerically Controlled (CNC) boring machine.

BACKGROUND OF THE INVENTION

Many products, such as automotive transmission housing and engineblocks, include precision bored holes. These holes are bored by cuttingtools supported by a boring tool which is driven by a boring machine. Inmany situations, the boring machine is computer numerically controlled(CNC) for reasons of flexibility, economics, and precision. Many CNCboring machines are capable of performing a wide range of operations ona product, including the boring of many different sizes of holes, by theautomatic selection of a previously adjusted boring tool from a toolbank.

However, many boring tools require manual adjustment by the machineoperator. Some currently used boring tools, such as the 3F-HBD Boringand Facing Head by Criterion Machine Works of Costa Mesa, Calif.; andthe tools of the Starflex Boring Tool Program of the Johne+ Company ofGermany require manual adjustment of the position of the cutting toolcorresponding to the desired bore diameter. Some tools include aninternal worm gear adjustable by the operator with an Allen wrench toslide a tool holder within a groove of a machine coupling member. Afterthe operator has manually positioned the cutting tool to bore thecorrect size diameter, the operator then tightens one or more fastenersto lock the position of the tool holder relative to the machine couplingelement. Thus, the clamping force holding the cutting tool on the boringtool is not maintained during adjustment and the tool is reclamped afteradjustment. This slow, inflexible, labor-intensive adjustment methoddetracts from the speed and economy of the CNC machine by requiring theoperator to stop the operation of the CNC machine during the period ofadjustment.

What is needed is a boring tool which permits adjustment of the positionof the cutting tool by operation of the machine, and not by manualreadjustment. Further, what is needed is a method of adjusting a boringtool on a CNC machine by software commands. The present inventionovercomes the drawbacks of the related art in novel and unobvious? ways.

SUMMARY OF THE INVENTION

One embodiment of the present invention is a unique method to adjust theposition of a cutting tool. Other embodiments include unique apparatus,methods, systems, and devices for adjusting the position of a cuttingtool.

A further embodiment of the present invention pertains adjusting theposition of a cutting tool used in a boring operation. The cutting toolis slidably coupled to a boring tool, and slidable in a first direction.The position of the cutting tool is adjusted by sliding an adjustmentmember in a second, different direction.

Yet another embodiment of the present invention pertains to a system forboring a hole with a computer numerically controlled machiningapparatus. The machining apparatus includes an electronic controllerwhich performs an algorithm to adjust the sliding position of a cuttingtool. The electronic controller places a surface of an adjustment memberin contact with a surface of a member that is not part of the boringtool, and applies a force thereacross.

Still another embodiment of the present invention pertains to a methodfor machining with a boring tool which includes a slidable cutting tooland a slidable adjusting member. The position of the cutting tool isadjusted with the aid of the boring machine by sliding the adjustmentmember in a direction different than the sliding direction of thecutting tool.

A further embodiment of the present invention pertains to a method foradjusting the position of a cutting tool by a first predeterminedamount. The cutting tool is moved this first predetermined amount bychanging the position of an adjusting member by a second amount which isgreater than the first amount.

Yet another embodiment of the present invention pertains to a boringtool having a cutting tool slidable on a first direction, and anadjustment member slidable in a second direction. The second directionis at least partly orthogonal to the rotational axis of the boring tool.The movement of the adjustment member is coupled to a movement of thecutting tool.

Further objects, embodiments, forms, benefits, aspects, features, andadvantages of the present invention can be obtained from thedescription, drawings, and claims provided herein.

DESCRIPTION OF THE DRAWINGS

FIG. 1A is an end view of an apparatus according to one embodiment ofthe present invention.

FIG. 1B is a side elevational view of the apparatus of FIG. 1A, andincluding a partial internal view.

FIG. 1C is an external side elevational view of the apparatus of FIG.1B.

FIG. 1D is an external side elevation view and partial cutaway view ofthe apparatus of FIG. 1C which includes a retaining ring.

FIG. 2A is a side elevational view according to another embodiment ofthe present invention.

FIG. 3A is an end view of an apparatus according to another embodimentof the present invention.

FIG. 3B is a side elevational view of the apparatus of FIG. 3A, withsome portions shown in cross-section.

FIG. 3C is a side elevational view of the apparatus of FIG. 3A with someportions shown in cross-section.

FIG. 4 is a schematic representation of a system for boring holes andadjusting a boring tool according to another embodiment of the presentinvention.

FIG. 5 is a side elevational view of an apparatus according to anotherembodiment of the present invention, and including a partial internalview.

FIG. 6A is a side elevational view of an apparatus according to anotherembodiment of the present invention, and including a partial internalview.

FIG. 6B is a side elevational view of an apparatus according to anotherembodiment of the present invention, and including a partial internalview.

FIG. 7 is a side elevational view of an apparatus according to anotherembodiment of the present invention, and including a partial internalview.

FIG. 8 is a side elevational view of an apparatus according to anotherembodiment of the present invention, and including a partial internalview.

FIG. 9 is a side elevational view of an apparatus according to anotherembodiment of the present invention, and including a partial internalview.

FIG. 10 is a side elevational view of an apparatus according to anotherembodiment of the present invention, and including a partial internalview.

FIG. 11 is a side elevational view of an apparatus according to anotherembodiment of the present invention.

FIG. 12A is a side elevational view of an apparatus according to anotherembodiment of the present invention.

FIG. 12B is a view of the apparatus of FIG. 12A as taken along line12B-12B of FIG. 12A.

FIG. 13A is a side elevational view of a portion of the apparatus ofFIG. 12A.

FIG. 13B is a view of the apparatus of FIG. 13A as taken along line13B-13B of FIG. 13A.

FIG. 14A is a side elevational view of a portion of the apparatus ofFIG. 12A.

FIG. 14B is a view of the apparatus of FIG. 14A as taken along line14B-14B of FIG. 14A.

FIG. 14C is a cross sectional view of the apparatus of FIG. 14B as takenalong line 14C-14C of FIG. 14B.

FIG. 15A is a side elevational view of a portion of the apparatus ofFIG. 12A.

FIG. 15B is a cross sectional view of the apparatus of FIG. 15A as takenalong line 15B-15B of FIG. 15A.

FIG. 16A is a side elevational view of an apparatus according to anotherembodiment of the present invention.

FIG. 16B is a view of the apparatus of FIG. 16A as taken along line16B-16B of FIG. 16A.

FIG. 17A is a side elevational view of a portion of the apparatus ofFIG. 16A.

FIG. 17B is a view of the apparatus of FIG. 17A as taken along line17B-17B of FIG. 17A.

FIG. 18A is a side elevational view of a portion of the apparatus ofFIG. 16A.

FIG. 18B is a view of the apparatus of FIG. 18A as taken along line18B-18B of FIG. 18A.

FIG. 18C is a cross sectional view of the apparatus of FIG. 18B as takenalong line 18C-18C of FIG. 18B.

FIG. 19A is a side elevational view of portion of the apparatus of FIG.16A.

FIG. 19B is a view of the apparatus of FIG. 19A as taken along line19B-19B of FIG. 19A.

FIG. 20 is a side elevational view of a boring tool according to anotherembodiment of the present invention.

FIG. 21 is a side elevational view of a boring tool according to anotherembodiment of the present invention.

FIG. 22 is a schematic representation of a system for boring a contouredhole according to another embodiment of the present invention.

FIG. 23 is a schematic representation of a system for boring a contouredhole according to another embodiment of the present invention.

FIG. 24 is a side elevational view of a boring tool according to anotherembodiment of the present invention.

FIG. 25 is an end view of the apparatus of FIG. 24 as taken along line25-25 of FIG. 24.

FIG. 26 is a schematic representation of a system for boring a contouredhole according to another embodiment of the present invention.

FIG. 27 is a cross sectional view of the apparatus of FIG. 26 as takenalong line 27-27 of FIG. 26.

FIG. 28 is a schematic representation of a system for boring a contouredhole according to another embodiment of the present invention.

FIG. 29 is a cross sectional view of the apparatus of FIG. 28 as takenalong line 29-29 of FIG. 28.

FIG. 30A is a side elevational and partial cutaway view of an apparatusaccording to another embodiment of the present invention.

FIG. 30B is a view of the apparatus of FIG. 30A as taken along line30B-30B of FIG. 30A.

FIG. 31A is a side elevational view of a portion of the apparatus ofFIG. 30A.

FIG. 31B is a view of the apparatus of FIG. 31A as taken along line31B-31B of FIG. 31A.

FIG. 32A is a side elevational view of a portion of the apparatus ofFIG. 30A.

FIG. 32B is a view of the apparatus of FIG. 32A as taken along line32B-32B of FIG. 32A.

FIG. 32C is a view of the apparatus of FIG. 32B as taken along line32C-32C of FIG. 32B.

FIG. 33 is an end elevational view of a portion of the apparatus of FIG.30A.

FIG. 34A is an end elevational view of a portion of the apparatus ofFIG. 30A.

FIG. 34B is a view of the apparatus of FIG. 34A as taken along line34B-34B of FIG. 34A.

FIG. 35 is a schematic, cross-sectional view of an apparatus accordingto another embodiment of the present invention.

FIG. 36 is a schematic, cross-sectional view of an apparatus accordingto another embodiment of the present invention.

FIG. 37 is a schematic, cross-sectional view of an apparatus accordingto another embodiment of the present invention.

FIG. 38 is a schematic, cross-sectional view of an apparatus accordingto another embodiment of the present invention.

FIG. 39 is a schematic, cross-sectional view of an apparatus accordingto another embodiment of the present invention.

FIG. 40 is a schematic, cross-sectional view of an apparatus accordingto another embodiment of the present invention.

FIG. 41 is a schematic, cross-sectional view of an apparatus accordingto another embodiment of the present invention.

FIG. 42 is a schematic, cross-sectional view of an apparatus accordingto another embodiment of the present invention.

FIG. 43 is schematic, cross-sectional view of an apparatus according toanother embodiment of the present invention.

FIG. 44A is a side elevational view of an apparatus according to anotherembodiment of the present invention.

FIG. 44B is an end elevational view of the apparatus of FIG. 44A.

FIG. 45A is a side elevational view of a portion of the apparatus ofFIG. 44A.

FIG. 45B is an end elevational view of the apparatus of FIG. 45A.

FIG. 46 A is a side elevational view of a portion of the apparatus ofFIG. 44A.

FIG. 46B is a view of the apparatus of FIG. 46A as taken along the line46B-46B of FIG. 46A.

FIG. 46C is a view of the apparatus of FIG. 46A as taken along the line46C-46C of FIG. 46B.

FIG. 46D is a view of the apparatus of FIG. 46A as taken along the line46D-46D of FIG. 46C.

FIG. 47A is a top plan view of a portion of the apparatus of FIG. 44B.

FIG. 47B is a side elevational view of the apparatus of FIG. 47A astaken along the line 47B-47B of FIG. 47A.

FIG. 48A is a top plan view of a portion of the apparatus of FIG. 44B.

FIG. 48B is a side elevational view of the apparatus of 48A as takenalong the line 48B-48B of FIG. 48A.

FIG. 49A is a side view of an apparatus according to another embodimentof the present invention.

FIG. 49B is an end elevational view of the apparatus of FIG. 49A.

FIG. 50A is a side elevational view of a portion of the apparatus ofFIG. 49A.

FIG. 50B is an end elevational view of the apparatus of FIG. 50A astaken along the line 50B-50B of FIG. 50A.

FIG. 51A is a side elevational view of a portion of the apparatus ofFIG. 49A.

FIG. 51B is a view of the apparatus of FIG. 51A as taken along the line51B-51B of FIG. 51A.

FIG. 51C is a view of the apparatus of FIG. 51A as taken along the line51C-51C of FIG. 51B.

FIG. 51D is a view of the apparatus of FIG. 51A as taken along the line51D-51D of FIG. 51C.

FIG. 52A is an top plan view of a portion of the apparatus of FIG. 49B.

FIG. 52B is a view of the apparatus of FIG. 52A as taken along a line52B-52B of FIG. 52A.

FIG. 53A is a top plan view of a portion of the apparatus of FIG. 49B.

FIG. 53B is a view of the apparatus of FIG. 53A as taken along the line53B-53B of FIG. 53A.

FIG. 54 is a schematic representation of a system for boring holes andadjusting a boring tool according to another embodiment of the presentinvention.

FIG. 55 is an end-view of a portion of the system of FIG. 54 as takenalong line 55-55 of FIG. 54.

FIG. 56 is a side elevational view of an apparatus according to anotherembodiment of the present invention.

FIG. 57 is a top elevational view of the apparatus of FIG. 56 with thetool holder slid to the right.

FIG. 58 is a top elevational view of the apparatus of FIG. 57 with thetop changeable tool holder removed, the bottom retained tool holdercentered, and with the retention members removed.

FIG. 59 is a side elevational view of the apparatus of FIG. 57, asviewed along the line 59-59 of FIG. 57.

FIG. 60 a is a bottom elevational view of a portion of the apparatus ofFIG. 56.

FIG. 60 b is a side elevational view of the apparatus of FIG. 60 a.

FIG. 60 c is a top plan view of the apparatus of FIG. 60 b.

FIGS. 60 a, 60 b, and 60 c are mutually orthogonal projections.

FIG. 60 d is a top plan view of a brake member, part of the apparatus ofFIG. 56.

FIG. 60 e is a side elevational view of the apparatus of FIG. 60 d.

FIG. 61 a is a side elevational view of the sliding adjustment memberfor the apparatus of FIG. 56.

FIG. 61 b is a top plan view of the apparatus of FIG. 61 a.

FIG. 62 a is a bottom plan view of a retained tool holder as used in theapparatus of FIG. 56.

FIG. 62 b is a side elevational view of the apparatus of FIG. 62 a.

FIG. 62 c is a top plan view of the apparatus of FIG. 62 b.

FIG. 62 d is a side elevational view of the apparatus of FIG. 62 c.

FIGS. 62 a, 62 b, 62 c, and 62 d are mutually orthogonal projections.

FIG. 63 a is an end elevational view of a brake member as used in theapparatus of FIG. 56.

FIG. 63 b is a side elevational view of the apparatus of FIG. 63 a.

FIG. 64 a is a side elevational view of a retention member as used inthe apparatus of FIG. 56.

FIG. 64 b is a top plan view of the apparatus of FIG. 64 a.

FIG. 65 a is a bottom plan view of a changeable tool holder as used inthe apparatus of FIG. 56.

FIG. 65 b is a side elevational view of the apparatus of FIG. 65 a.

FIG. 65 c is a top plan view of the apparatus of FIG. 65 b.

FIGS. 65 a, 65 b, and 65 c are mutually orthogonal projections.

FIG. 66 a is a top elevational view of a portion of an apparatusaccording to another embodiment of the present invention.

FIG. 66 b is a top plan view of the apparatus of FIG. 66 a with thechangeable tool holder slid to a different position.

FIG. 67 a is a bottom plan view of a coupling element and couplingelement body used with the apparatus of FIG. 66 a.

FIG. 67 b is a side elevational view of the apparatus of FIG. 67 a.

FIG. 67 c is a top plan view of the apparatus of FIG. 67 b.

FIGS. 67 a, 67 b, and 67 c are mutually orthogonal projections.

FIG. 68 a is a side elevational view of an adjustment member used withthe apparatus of FIG. 66 a.

FIG. 68 b is a side elevational view of the apparatus of FIG. 68 a.

FIG. 69 a is a bottom plan view of a retained tool holder used with theapparatus of FIG. 66 a.

FIG. 69 b is a side elevational view of the apparatus of FIG. 69 a.

FIG. 69 c is a top plan view of the apparatus of FIG. 69 b.

FIGS. 69 a, 69 b, and 69 c are mutually orthogonal projections.

FIG. 70 a is a retention member used with the apparatus of FIG. 66 a.

FIG. 70 b is a top plan view of the apparatus of FIG. 70 a.

FIG. 70 c is a side elevational view of the apparatus of FIG. 70 b.

FIGS. 70 a, 70 b, and 70 c are mutually orthogonal projections.

FIG. 71 a is a bottom plan view of a changeable tool holder used withthe apparatus of FIG. 66 a.

FIG. 71 b is a side elevational view of the tool holder of FIG. 71 a.

FIG. 71 c is a top plan view of the apparatus of FIG. 71 b.

FIGS. 71 a, 71 b, and 71 c are mutually orthogonal projections.

FIG. 72 a is a front elevational view of an apparatus according to oneembodiment of the present invention, with the retention members removed.

FIG. 72 b is a side elevational view of the apparatus of FIG. 72 a, withthe retention members removed.

FIG. 73 a is a top view of the apparatus of FIG. 72 a.

FIG. 73 b is a top view of the apparatus of FIG. 73 a with the retentionmembers removed, and in partial cut-away.

FIG. 74 a is a bottom plan view of a portion of the apparatus of FIG. 72a.

FIG. 74 b is a side elevational view of the apparatus of FIG. 74 a.

FIG. 74 c is a top plan view of the apparatus of FIG. 74 b.

FIGS. 74 a, 74 b, and 74 c are mutually orthogonal projections.

FIG. 75 a is a side elevational view of an adjustment member used in theapparatus of FIG. 72 a.

FIG. 75 b is a top plan view of the apparatus of FIG. 75 a.

FIG. 75 c is a side elevational view of a brake member used in theapparatus of FIG. 72 a.

FIG. 75 d is a top plan view of the apparatus of FIG. 75 c.

FIG. 75 e is a side elevational view of another brake member used in theapparatus of FIG. 72 a.

FIG. 75 f is a top plan view of the apparatus of FIG. 75 e.

FIG. 76 a is an end elevational view of the retention member used in theapparatus of FIG. 73 a.

FIG. 76 b is a top plan view of the apparatus of FIG. 76 a.

FIG. 76 c is a front elevational view of the apparatus of FIG. 76 b.

FIG. 77 a is a side elevational view of a changeable tool holder used inthe apparatus of FIG. 72 a.

FIG. 77 b is a top plan view of the apparatus of FIG. 77 a.

FIG. 77 c is a bottom plan view of the apparatus of FIG. 77 b.

FIGS. 77 a and 77 b are mutually orthogonal projections.

FIG. 78 a is a side elevational view of a changeable tool holder used inthe apparatus of FIG. 72 a.

FIG. 78 b is a top plan view of the apparatus of FIG. 78 a.

FIG. 78 c is a bottom plan view of the apparatus of FIG. 78 b.

FIGS. 78 a and 78 b are mutually orthogonal projections.

FIG. 79 is a top plan view of a coupling element body according toanother embodiment of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

For the purposes of promoting an understanding of the principles of theinvention, reference will now be made to the embodiments illustrated inthe drawings and specific language will be used to describe the same. Itwill nevertheless be understood that no limitation of the scope of theinvention is thereby intended, such alterations and furthermodifications in the illustrated devices, and such further applicationsof the principles of the invention as illustrated therein beingcontemplated as would normally occur to one skilled in the art to whichthe invention relates.

The present invention relates both to apparatus and method by which theoperator can adjust the sideways location of a cutting tool used in amachining operation; for example, a cutting tool used for boring holeswith a CNC boring machine. According to one embodiment of thisinvention, the cutting tool or cutting tool holder is coupled to themachine coupling element, and can be moved relative to the couplingelement. In one embodiment, the relative movement of the cutting tool orcutting tool holder is sliding movement, although the present inventionis not limited to sliding movement. The sliding movement of the toolholder relative to the coupling element is controlled at a frictionalinterface. The tool holder is held firmly within the coupling element bya predetermined amount of friction. This amount of friction issufficient to hold the tool in place during machining operations.However, this friction can be overcome in order to adjust the positionof the cutting tool by applying a sufficiently high sideways load.

In another embodiment, the cutting tool holder and coupling memberinclude a contact or frictional force actuating mechanism. The mechanismcan vary the contact or frictional force between the tool holder and thecoupling member, thus varying the frictional force which holds the toolholder in place. The actuating mechanism can be actuated to a firstposition or state which applies a first contact force between the toolholder and the coupling mechanism, resulting in a first frictional forcerestraining movement of the sliding tool holder. The mechanism is alsoactuatable to a second position or state in which a second contact forceis applied between the tool holder and the coupling member, resulting ina second frictional force restraining sliding motion of the tool holder.The second contact force is greater than the first contact force, andthe second frictional force is greater than the first frictional force.

The mechanism is actuated to the first state when the lateral positionof the tool holder is adjusted. The frictional load of the first stateis preferably greater than the corresponding lateral loads associatedwith machining, but less than the lateral load that can be applied by amachining apparatus such as a boring machine to laterally adjust theposition of the cutting tool. The actuating mechanism is actuated to thesecond state prior to machining of an object. Preferably, the frictionalload of the second state is greater than the lateral loads encounteredduring machining, and also greater than the lateral loads applied duringadjustment of the position of the cutting tool. However, the presentinvention also contemplates those embodiments in which the frictionalloads from both the first state and the second state are greater thanthe loads applied during machining, but less than the loads appliedduring adjustment of the position of the cutting tool. Further, thepresent invention contemplates those embodiments in which the frictionalload from the first state is less than the lateral load encounteredduring machining. As non-limiting examples, the contact force actuatingmechanism can include an electromagnet, an electromagnetic solenoid, ahydraulic piston, a hydraulic bladder, and/or centrifugal weights.

One embodiment of the present invention relates to a method formachining a bore. In this method an electronically controlled boringmachine is commanded by an operator or by software to place a surface ofa boring tool in contact with a static surface. The operator or softwarethen commands the boring machine to apply a force against the staticsurface, this pressing of the boring tool against the static surfaceresulting in sliding of the cutting tool on the boring tool relative tothe body of the boring tool. The boring machine moves the boring tool apredetermined distance against the static surface, this distance havingbeen calculated to set the cutting tool in a proper position for thenext boring operation. The cutting tool is held in place by frictionrelative to the boring tool body, and this friction maintains thecutting tool in the proper position during machining. However, thefrictional force is of a low enough value so as to be overcome by thelateral force exerted by the boring machine against the static surface.

In another embodiment, the present invention relates to an apparatus forboring a hole with a boring machine. The boring apparatus includes atool holder which is slidably coupled to a boring machine couplingelement. The sliding interface between the tool holder and the couplingelement includes a first contact surface of the tool holder that is incontact with a second contact surface of the coupling element. Apredetermined normal force can be applied between the contact surfacesto create a predetermined frictional force between the first and secondcontact surfaces. This predetermined frictional force resists sliding ofthe tool holder relative to the coupling element. The predeterminedfrictional force is sufficient to restrain the lateral position of thetool holder when the tool holder is boring a hole, but is of a magnitudeinsufficient to restrain the lateral position of the tool holder duringlateral adjustment of the tool holder relative to the coupling element.Some embodiments of the present invention utilize a spring to urge thefirst contact surface against the second contact surface. Otherembodiments include the spring and also an adjusting element such as afastener which permits adjustment of the force exerted by the spring tourge the first and second contact surfaces together.

Other embodiments include adjusting the friction in a boring tool bylessening of the torque of the set screws that maintain the slidingcutting tool in place. Typically, these set screws are adjusted to ahigh level of torque to maintain the sliding tool holder in place at alltimes. For example, the torque applied to the set screws may be therecommended maximum torque for the screw. This high torque createssubstantial holding friction which prevents any lateral movement of thetool holder without first loosening one or more of the set screws.Typically, the screw is loosened, the tool position is adjusted, thescrew is retightened, and machining resumes.

According to one embodiment of the present invention, the set screws areadjusted to a level of torque that is less than the recommended torquefor holding the tool in place. This lower level places sufficientfriction on the sliding tool holder to maintain it in place duringmachining, but insufficient friction to maintain the sliding tool holderin place during on-machine adjustment as described herein. Thisadjustment can be performed with the boring tool coupled to the boringmachine, and without the need to stop the operation of the machine tomake manual adjustments to the tool position. In some embodiments of thepresent invention, the set screws include a locking device or lockingmethod to insure that the set screw retains a particular angularposition and therefore a particular amount of friction. As one example,the threads of the set screws can be coated with a locking compound. Asanother example, the threads of the set screw can have a shape thatresults in interference with the mating threads. Those of ordinary skillin the art will recognize other methods for retaining a screw inposition.

The various FIGS. shown in this application include schematicrepresentations of systems, methods, and apparatus.

FIGS. 1A, 1B, and 1C show an end view and two side views, respectively,of one embodiment of the present invention. A boring tool 20 accordingto the present invention includes a cutting tool 25 held at the end andside of a tool support 30 that rigidly extends from a tool holder 35.Cutting tool 25 is a conventional cutting tool of any shape and materialsuitable for a boring operation. FIG. 1A also includes a static member50 which preferably includes a static surface 51. By way of non-limitingexamples, static member 50 can be a portion of the boring machine, theobject to be machined, or a fixture attached to the boring machine or tothe object.

Cutting tool 25 is used to machine an object in a conventional manner.Cutting tool 25 is rotated about the central axis of the boring tool,and brought into contact with an object to be machined. The outermostcorner of cutting tool 25 contacts the surface of the object to bemachined, and removes material from the object as the cutting tool bothrotates about axis 22 and translates relative to the object.

Machining of the object places a three dimensional load on the cuttingtool. Referring to FIG. 1C, there is an axial force X which is parallelto axis 22. There is also a lateral load Y, which can also be thought ofas a radially-directed load, which is a force on cutting tool 25 that issubstantially parallel (or includes a parallel component) to the slidingdirection of tool holder 35. Finally, there is a third load (not shownon FIG. 1C) acting in a tangential direction which is perpendicular toboth forces X and Y, and is related to the frictional drag and cuttingforces of the cutting tool on the object.

It is believed that the lateral load Y encountered during machiningwhich is parallel to the sliding motion of the cutting tool holder has arelatively small value compared to the other forces acting on thecutting tool. Therefore, although the axial and tangential forces actingon the cutting tool in response to axial and rotary motion of thecutting tool, respectively, can be significant, it is believed that thelateral load Y is lesser in value. Further, it is believed that somemachining apparatuses, including some CNC boring machines, are capableof applying a sideways load to a tool holder that is parallel to Y andlarger than the Y-direction loads encountered during machining.Therefore, a sliding tool holder which is restrained from sliding motionby a frictional load which is greater than the load Y encountered duringmachining will be sufficient to maintain the tool holder in place duringmachining. Further, by providing a frictional force which is less thanthe amount of lateral load which can be applied by the machiningapparatus through the tool holder against a static member, it ispossible for the machining apparatus to laterally reposition the cuttingtool, while maintaining the cutting tool clamped to the coupling memberin a manner suitable for subsequent machining.

Tool holder 35 is slidable by a T-joint 37 within coupling element body38 of machine coupling element 45. Although a T-joint 37 in asquared-off configuration is shown and described, the present inventionalso contemplates other types of sliding joints between tool holder 35and machine coupling element 45, including a dovetail joint. Machinecoupling element 45 locks apparatus 20 to the CNC machine at a couplinginterface 46, and is powered by the CNC machine so as to rotate tool 25within the bore to be machined. The present invention is not limited tothe configuration of coupling interface shown, and can include anycoupling interface which provides powering and location of the boringtool 20. Further, although machine coupling device 45 is shown anddescribed as interfacing to both tool holder 35 and a boring machine,the present invention further contemplates the use of intermediatecoupling members between coupling element 45 and the boring machine.

FIG. 1B includes a partial internal cutaway view of boring tool 20.Machine coupling element 45 includes an internal frictional adjustmentapparatus 40. Apparatus 40 includes an adjusting member 41 that can bemanually adjusted, such as a bolt threadably retained within an internalbore of coupling element 45. Adjusting member 41 places contact pressureon an adjustment plate 42. Adjustment of member 41 against plate 42results in a change in the force exerted by springs 43 against movablemember or brake plate 44. The present invention contemplates springs 43which can be any kind of spring-biasing member, including coil springs,torsional springs, cantilever springs, leaf springs, and gas orhydraulic springs. Further, although what is shown and described aresprings placed in compression and urging the sliding tool holder awayfrom the body of the coupling member, the present invention alsocontemplates those embodiments in which the springs are adapted andconfigured to urge the sliding tool holder toward the body of thecoupling member. As one example, referring to FIG. 1B, the presentinvention contemplates those embodiments in which adjusting member 41 isthreadably coupled to plate 42, such that rotation of member 41 pullsplate 42 toward the conical driven end of apparatus 20. In thisembodiment, springs 43 would be attached at one end to plate 42 and atthe other end to tool holder 35. The springs are in tension and urgetool holder 35 toward the conical end of apparatus 20.

Movable member or brake plate 44 includes a contact surface 44 a with africtional coating 47 comprising a frictional material such as a brakepad material. In some embodiments, a similar frictional coating 47 isapplied to a contact surface 37 a of T-joint 37 that is in contact withsurface 44 a. Adjustment of member 41 results in adjustment of thenormal force acting between contact surface 37 a and 44 a. Thispredetermined normal force establishes a predetermined frictional forcebetween contact surfaces 37 a and 44 a, and thus controls the amount ofsliding friction at the interface of surfaces 44 a and 37 a. Thisfriction is adjusted so that tool holder 35 is prevented from slidingduring boring or other machining operations, but can be adjustedsideways with a force sufficient to overcome the frictional forcebetween internal surfaces 37 a and 44 a.

Although what has been shown and described depict a frictional interfacebetween contact surfaces 37 a and 44 a, the present inventioncontemplates other locations for a frictional interface. For example,frictional contact can be utilized between contact surface 37 b ofT-joint 37 and surface 38 b of coupling element body 38. In addition,the frictional interface can be established between mating contactsurface 35 c of holder 35 and contact surface 38 c of element body 38.Preferably, the frictional interface is established against any surfaceof the sliding tool holder, such that the tool holder is restrained fromsliding relative to the coupling member.

The present invention contemplates application of frictional coating 47to either one or both of the contact mating surfaces. In addition to theuse of a frictional material such as a brake pad material for frictionalcoating 47, the present invention further contemplates other types ofmaterials applied to one or more contact surfaces, including surfacecoatings for increased resistance to abrasion, wear, galling, and thelike. Such coatings may provide this increased resistance by a drop inthe coefficient of friction. In such applications, the requiredfrictional force can be achieved by increasing the normal or contactforce between contacting surfaces. Non-limiting examples of varioussurface coatings providing increased resistance to abrasion, wear,galling, and the like include the use of a Babbitt bearing alloy,polyvinyl chloride polymer, polyethylene polymer, TFE fluorocarbonpolymer, molybdenum-disulfide (with or without solid film lubricantssuch as graphite), and oil. Further, as non-limiting examples, thepresent invention contemplates the use of thermochemical coatings,hot-dipped coatings, plating, mechanical cladding, deposited coatings,and heat treating of the contact surfaces to achieve the appropriatewear and frictional characteristics.

Some embodiments of the present invention use one pair of contactsurfaces to provide most of the frictional force holding the tool holderstationary relative to the coupling element during machining. Othercontact surfaces between the tool holder and coupling element caninclude surface finishes or surface coatings which have a lowcoefficient of friction. By limiting the high coefficient of frictioncoatings, materials, and surfaces to a single pair of mating contactsurfaces, the total amount and location of sliding friction between thetool holder and coupling element can be reliably and accuratelymaintained.

FIG. 1D depicts a side elevational view and partial cutaway view ofanother embodiment according to the present invention. The use of asingle prime (XX.X′) or double prime (XX.X″) with an element number(XX.X) refers to an element that is the same as the non-prime element(XX.X) previously described or depicted except for the differences whichare described or depicted hereafter. FIG. 1D shows apparatus 20′, whichis substantially the same as apparatus 20, but further includes aretaining ring assembly 48 which is a safety device to prevent slidingtool holder 35 from sliding out of contact with coupling member 45, suchas can occur during rotation at high speed. Under conditions of highrotational speed, a rotational mass imbalance of cutting tool holder 35,such as that created by tool support 30, can result in creation of acentrifugal load larger than the frictional load which restrainsmovement of cutting tool holder 35. Under these conditions, cutting toolholder 35 can move laterally. Retaining ring 48 limits the slidingmovement of tool holder 35 so that there is contact between tool holder35 and body 38 of coupling member 45.

Retaining ring 48 has a split 48 a along one side. Split 48 a permitsring 48 to slide in close tolerance over the outer diameter of body 38.A fastener 48 b can be tightened to retain compression of ring 48 alonginner diameter 48 c against the outer surface of body 38. A second,larger inner diameter 48 d provides clearance to the outer surface ofcutting tool 35, this clearance being sufficient for adjustment of theposition of cutting tool 25. However, this clearance is insufficient fordisengagement of cutting tool 35 from body 38.

FIG. 11 depicts a side elevational view of a boring tool apparatus 20″according to another embodiment of the present invention. Apparatus 20″is substantially similar to apparatus 20, but includes a plurality ofset screws 19 for clamping tool holder 35″ to body 38″. Apparatus 20″does not necessarily include the internal frictional adjustmentapparatus 40 of boring tool 20. Set screws 19 are adjusted to apredetermined level of torque. This predetermined level of torque placessufficient friction on sliding tool holder 35″ to maintain it in placeduring machining, but insufficient friction to maintain sliding toolholder 35″ in place during on-machine adjustment as described herein.Set screws 19 can include various locking devices or locking methodsknown to those of ordinary skill in the art which insure that the setscrews maintain a particular angular position and therefore a particularamount of friction.

One embodiment of the present invention similar to apparatus 20″includes a boring tool manufactured by Criterion Machine Works of CostaMesa, Calif. A Criterion boring tool part no. DBL-204 head is coupled toa Criterion CB3-CV50 tapered adapter body. This boring tool includes anoriginal equipment worm-gear mechanism to adjust the position of thecutting tool. This worm-gear is removed. The three set screws whichrestrain the cutting tool holder from sliding relative to the adapterbody are torqued to approximately 40 inch pounds. The boring tool isinstalled on a SPN63 (serial no. 46600031) CNC boring machinemanufactured by Niigata Machinery of Schaumburg, Ill. The boring tool isautomatically adjusted by the boring machine by placing a surface of theboring tool against a static member, with the CNC machine applying alateral load sufficient to adjust the lateral position of the cuttingtool. The boring tool can machine a plurality of bores while maintainingthe coupling of the boring tool to the boring machine, and maintainingthe same clamping of the cutting tool to the boring tool. It is believedthat the force required to slide the tool holder relative to the adapterbody is about 370 pounds force.

FIG. 4 schematically depicts a system 80 according to another embodimentof the present invention. An electronically controlled machine (such asa CNC boring machine) 82 uses a slidably adjustable boring tool 20 tobore a hole 84 in a workpiece or product 86, such as a transmissioncase. Boring machine 82 includes a drive unit 88 which releaseablycouples to coupling element 45 in a conventional manner. Drive unit 88provides power from a motor 90 to rotate boring tool 20 during theboring process. In one embodiment, motor 90 and drive unit 88 maintainboring tool 20 in a fixed location, and machining of bore 84 isaccomplished by mounting product 86 to a table 92 which is capable ofmovement in multiple axes. However, the present invention alsocontemplates lateral and axial movement of boring tool 20 relative totable 92, or lateral and axial motions of both boring tool 20 and table92. Preferably, machine 82 includes a computer 94 which includes memory95 for storing a software algorithm 96. Machine 82 preferably includes aplurality of position sensors (not shown) which detect translationalmovement of table 92 and/or drive unit 88. Although a CNC boring machinehas been shown and described, the present invention also contemplatesboring machines which are electronically controlled without the use of acomputer, as well as boring machines which are mechanically controlled.

One manner of adjusting the location of cutting tool 25 of boring tool20 is as follows. The operator machines a feature on the object such asa bore, measures a characteristic of the feature such as the diameter ofthe bore, and determines the magnitude of error in the size of thefeature. The operator then issues instructions to the CNC machine, oralternatively runs software on the CNC machine or electronicallypositions an electronically controlled boring machine or manuallypositions a manually controlled boring machine, to adjust the positionof cutting tool by a distance corresponding to the measured error. Inthe case of an electronically or mechanically controlled boring machinethat is not computer controlled, the operator uses the appropriateelectrical or manual controls for sideways movement of the boring tool.Further, the present invention contemplates those embodiments in whichthe measurement of the diameter of the bore is performed automaticallyby one or more position sensors of the electronically controlled machine82. The present invention contemplates the use of any type of positionsensor, including LVDTs, potentiometers, lasers, or any other devicesknown in the art.

Adjustment of the lateral position of cutting tool 25 relative tocoupling element 45 is accomplished by placing an external surface 21 oftool holder 35 against a surface 51 of a static member 50. In oneembodiment of the present invention, drive unit 88 and the coupledboring tool are moved laterally at a first, high travel rate untilsurface 21 is close to surface 51, at which time a slower travel rate isused. This placement of external surface 21 against rigid surface 51 isconsistent with the direction in which tool holder 35 slides relative tocoupling element 45. For example, for a boring tool 20 as shown in FIG.1B, the rigid member 50 extends vertically as shown on FIG. 1B andtouches the side external surface 21 of tool holder 35. Forces exertedbetween rigid member 50 and surface 21 are at least partly parallel tothe direction of sliding motion of tool holder 35 relative to couplingelement 45. However, the present invention is not limited to the use ofa vertically oriented rigid member, and contemplates any orientation fora surface that permits contact between the surface and an externalsurface of the tool holder for exerting a force for sliding movement ofthe tool holder 35 relative to coupling element 45. In some embodimentsof the present invention, the boring tool is moved relative to a staticmember. In other embodiments, a member, preferably a member undercontrol of the CNC machine, is moved relative to a static boring tool.

After placement of surface 21 against surface 51, the machine pressesthe two surfaces together. This pressing together of the two surfacesdoes not result in sliding movement of tool holder 35 until the staticfriction force holding tool holder 35 relative to coupling element 45 isovercome. Once the lateral force exerted by the machine overcomes thestatic frictional force, tool holder 35 moves laterally as long as theforce applied by the machine is greater than the dynamic (or moving)frictional force between tool holder 35 and coupling element 45. Themachine continues to apply a lateral force until position sensors (notshown) of the electronic machine, or alternatively the human operator ofa manually controlled machine, indicates that sufficient movement hasoccurred to place the cutting tool at the new, proper location.

The CNC boring machine moves tool 20 sideways with a force sufficient toovercome the friction between surfaces 37 a and 44 a, as well as anyother sliding contact surfaces. In one embodiment of the presentinvention, the drive unit and boring tool are moved laterally at a slowrate. The present invention also contemplates those embodiments in whichtool 20 is held stationary and table 92 moves laterally relative toboring tool 20, and also those embodiments in which both boring tool 20and table 92 move relative to each other. The force required to move thecutting tool relative to the coupling member can be a first, highervalue to overcome static or breakaway friction, followed by a second,lower value to overcome moving or dynamic friction. The machine appliesthis force until it has moved tool holder 35 sideways by the distancenecessary to correctly size the bore. This distance corresponds to adimensional error previously determined by the operator.

As seen in FIG. 1A, moving the tool holder 20 in the direction indicatedby the “larger” arrow against static member 50 results in tool holder 35and cutting tool 25 becoming offset from machine coupler 45 in adirection to bore a larger hole. Moving tool holder 20 in the directionindicated by the “smaller” arrow against rigid member 50 results in toolholder 35 and cutting tool 25 becoming offset from machine coupler 45 ina direction to bore a smaller hole. If it is desired to increase thesize of the machined bore, then the lateral position of the cutting toolholder would be moved as indicated by the “larger” arrow against staticmember 50. Correspondingly, if it is desired to produce a smaller bore(such as on a new object), then the sliding tool holder will be movedrelative to coupling member 45 in the direction indicated by the“smaller” arrow. Although what has been shown and described is a methodincluding machining, measuring, calculating an error, and re-machining afeature such as a bore, the present invention contemplates the machiningof any type of feature on an object which can be machined with aslidably adjustable tool holder. In some circumstances it is desirableto reset the position of the cutting tool holder, such as from a“unknown” position to a “known” position.

In these circumstances, one embodiment of the present inventioncontemplates a first sliding of the cutting tool relative to thecoupling member in a first direction to a first position, especially aposition for machining a small bore. This first sliding is accomplishedafter placing a first surface of the boring tool in contact with thestatic member. In one embodiment, this first sliding is designed toaccept a boring tool having a cutting tool in an unknown position, andby the first sliding place the cutting tool in a first known position,such as a reference position.

After this first sliding, a second surface of the boring tool is placedin contact with a second surface of the static member. Preferably, thesecond surface of the boring tool is on a side of the boring toolopposite of the first surface. As a result of sliding motion of themachining apparatus table relative to the machining apparatus driveunit, a force is exerted on a surface slidable with the cutting toolholder of the boring tool to move the cutting tool holder in a seconddirection opposite of the first direction to a second, known position.The second sliding moves the cutting tool from the first known referenceposition to a position for ready for machining an object.

The present invention contemplates a static member 50 for reacting andresisting the lateral adjustment force exerted by the boring machine.Preferably, static member 50 reacts to the lateral adjustment force withlittle movement of the member itself. In this way, the lateral movementof the coupling member during adjustment as measured by one or moreposition sensors of machine 82 is primarily the sliding movement of thecutting tool holder relative to the coupling member, and not theflexibility or “give” of the static member. However, the presentinvention also contemplates those embodiments in which member 50 hasflexibility, including embodiments in which there is compensation forthis flexibility. Therefore, some embodiments include an algorithm inwhich the amount of sliding motion adjusting the position of the cuttingtool as measured by the position sensors of the machining apparatus isdifferent than the machining error calculated by the operator. Forexample, the algorithm can include adding or subtracting a fixed amountto the calculated error, and/or multiplying the error by a constantgreater than or less than one. As another example, the present inventioncontemplates those embodiments in which static member 50 freely moves asmall distance after being contacted by the boring tool, such as thecase where the contact surface of the static member is coupled to abutton or sensor which provides a signal to the operator or electroniccontroller that contact between the boring tool and the static memberhas been established. As another example, it may be known that aparticular static member deflects a particular amount before the cuttingtool holder slides relative to the coupling member.

The present invention contemplates a static member 50 comprising aseparable fixture bolted or otherwise attached to the boring machine, astatic surface of the product being bored, or any other static surfacewhich is within the travel distance of the table relative to the boringmachine. Although what has been shown and described is a system 80 whichincludes a slidably adjustable boring tool 20, the present inventioncontemplates the use of any slidably adjustable boring tools describedherein with system 80. Further, although what has been shown anddescribed is a slidably adjustable boring tool 20 in which the cuttingtool holder 35 slides relative to coupling member 45, it is understoodthat repositioning of the cutting tool is contemplated, and the use ofany tool holder which permits that repositioning is included in thepresent invention.

Yet another embodiment of the present invention contemplates a methodfor machining a characteristic of an object in which either the operatoror electronically controlled machine 82 adjusts the position of cuttingtool 25 while maintaining the boring tool coupled to the driving elementand maintaining clamping of the tool holder relative to the couplingmember to a first, initial position for rough cutting of thecharacteristic on the object. The operator or electronic controller thenslidably adjusts the position of cutting tool 25 to a second positionfor a second, fine cut of the characteristic without making ameasurement of the characteristic after the first, rough cut.

FIG. 2A shows a side view of slidably adjustable boring tool 120according to another embodiment of the present invention. The use hereinof an “N” hundred-series prefix (NXX) with an element number (XX.X)refers to an element that is the same as the non-prefixed element (XX.X)previously described or depicted, accept for the differences which aredescribed or depicted hereafter.

Boring tool 120 includes a tool holder 135 that is slidably adjustablyrelative to coupling element 145 by overcoming the friction forces at africtional interface between coupling element 145 and tool holder 135.

Body 138 of coupling 145 preferably includes a pair of frictionaladjustment apparatus 140. Each adjustment apparatus 140 includes anadjusting member 141 such as a threaded fastener.

One end of adjusting element 141 bears against a spring 143. Rotation ofadjusting element 141 results in a change in the force exerted by spring143 against a brakeplate 144. Brakeplate 144 includes a contact surface144A which contacts surface 135A of tool holder 135. Preferably, one orboth of contact surfaces 144A and 135A include a frictional coating 147for increasing or modifying the coefficient of friction between the twocontact surfaces.

Although the use of a friction coating 47 and 147 has been shown anddescribed for increasing the coefficient of friction between the contactsurfaces, the present invention also contemplates the use of materialsand surface coatings on one or both of the contact surfaces which do notincrease the coefficient of friction, but provide a known and consistentcoefficient of friction. For example, some embodiments of the presentinvention include surface coatings between the contact surfaces thatdecrease the coefficient of friction, but in these cases the totalfrictional force which clamps holder 35 relative to coupling element 45can be increased by increasing the normal force between the contactsurfaces. Some embodiments of the present invention utilize a lowcoefficient of friction surface coating combined with a high normalforce particularly where the surface coating provides resistance togalling, adequate wear resistance, and adequate durability. Regardlessof the coefficient of friction between the contact surfaces, thefrictional force clamping tool holder 35 relative to coupling element 45is sufficient to maintain the location of cutting tool 25 duringmachining, and the frictional force is insufficient to withstand thelateral load imposed against the rigid surface during adjustment.

Preferably, the contact surfaces are parallel to each other. As can beseen in FIG. 2A, both contact surfaces 135A and 144A are displaced 45°relative to centerline 122 of boring tool 120. However, the presentinvention also contemplates those embodiments in which the contactsurfaces are not parallel to each other, such that an edge of onecontact surface makes line contact with the other contact surface.Further, the present invention contemplates those embodiments in whichthe contact between brakeplate 144 and tool holder 135 is not coatedwith frictional material 147. In these embodiments contact betweencontact surfaces 135A and 144A does not provide the primary frictionalload for clamping tool holder 135 relative to coupling element 45.Instead, the contact surfaces are the primary means for imparting anormal force onto other surfaces of tool holder 135 that are in contactwith surfaces of body 138 of coupling element 145. Therefore, thepresent invention also contemplates creating a normal force between afirst pair of contact surfaces, and providing the primary frictionalforce between a different pair of contact surfaces.

FIGS. 3A, 3B, and 3C present one front and two side elevational views,respectively, of an apparatus according to another embodiment of thepresent invention. These figures depict various views of a boring tool220 according to another embodiment of the present invention. Boringtool 220 includes preferably a pair of frictional adjustment apparatus240 which provide clamping between tool holder 235 and body 238 ofcoupling element 245. Each adjustment apparatus 240 includes a staticmember 244 that is fastened by a fastener 241 to body 238. Member 244includes a contact surface 244A that is in contact with a mating contactsurface 235A of tool holder 235. Preferably, both contact surfaces 244Aand 235A are generally parallel, and both are preferably displaced at anacute angle 223 relative to centerline 222. Tightening of fasteners 241into body 238 provides a normal force between contact surfaces 235A and244A. However, the normal force between the contact surfaces is afraction of the axial load within the fasteners 241. This fractiondepends upon the sine of angle 223. For example, for an angle 223 of30°, the normal force exerted between the contact surfaces is only halfof the axial load within the fasteners 244, since the fasteners 244 areoriented parallel to centerline 222. Therefore, the amount of normalforce between the contact surfaces can be adjusted by selection of angle223. As angle 223 approaches zero, the normal force between the contactsurfaces decreases toward zero. In this way, the normal load betweencontact surfaces is controlled by selection of the angle 223 and thetorque applied to fasteners 241. Thus, the present inventioncontemplates those embodiments such as boring tool 220 in which thefrictional adjustment apparatus does not require a spring for adjustingthe normal load.

It is to be understood that the present invention contemplates thoseembodiments in which the frictional force which restrains movement ofsliding tool holder 35 results from forces applied parallel to axis 22,in either direction. For example, some of the springs, hydraulicpressure, solenoids, electromagnets, and centrifugal weights shownherein and related and equivalent devices can be used to urge thesliding tool holder apart from the coupling member. However, the presentinvention also contemplates those embodiments in which the springs,hydraulic pressure, solenoids, electromagnets, and centrifugal weightsand related and equivalent devices are used to urge the sliding toolholder toward the coupling element. For those embodiments in which thetool holder and coupling element are urged apart, the axial load Ximparted to the cutting tool during machining opposes this urging forceon the boring tool, and thus reduces the net normal force acting betweenfrictional surfaces. This net reduction in normal forces corresponds toa net reduction in the frictional force which restrains sliding movementof the tool holder.

For those embodiments in which the tool holder and coupling member areurged together, the axial load X applied on the cutting tool duringmachining increases the normal force applied between frictionalsurfaces. In this latter example the frictional forces which restrainlateral movement of the tool holder are increased during machining. Forthose embodiments in which boring tool 20 is arranged and configuredsuch that the sliding tool holder is urged toward the coupling member,the X-direction machining forces act in what can be thought as a“self-energizing” manner, i.e., use of the cutting tool increases thefrictional force which restrains the tool holder from sliding.

FIG. 5 shows a side elevational view of an apparatus 320 according toanother embodiment of the present invention. Apparatus 320 is a boringtool which includes a slidably adjustable cutting tool 325. Cutting tool325 is fixedly supported, such as by a tool support 330, which extendsfrom a slidably adjustable tool holder 335. Tool holder 335 preferablyincludes a joint 337 such as a dovetail joint or T-joint which slidinglycouples to a complementary-shaped joint of a coupling element body 338.Coupling element body 338 is part of a coupling element 345. Couplingelement 345 preferably includes a conically-shaped end and a couplinginterface 346, both of which locate boring tool 320 in a drive unit suchas drive unit 88 of electronically controlled machine 82 (referring toFIG. 4). Referring again to FIG. 5, apparatus 320 includes a frictionadjustment apparatus 340 which applies a normal force between facingcontact surfaces of apparatus 320.

Apparatus 320 includes means 340 for applying a friction force betweencontact surfaces for clamping the sliding cutting tool to the boringtool. Means 340 includes a chamber 351 within coupling element body 338.A piston 344 is slidable within chamber 351. A sealing member 344.1provides a seal between piston 344 and the walls of chamber 351. Apressure adjusting screw 353 is threadably received within a bore ofbody 338. Chamber 351 includes hydraulic fluid 352. Rotation ofadjusting screw 353 either inward or outward relative to body 338,either increases or decreases, respectively, the amount of fluid 352displaced from the bore. This change in the amount of displaced fluidresults in a corresponding change in the position of piston 344. Forexample, inward rotation of screw 353 results in movement of piston 344toward cutting tool holder 335. After screw 353 has been movedsufficiently to bring piston 344 in contact with tool holder 355, anysubsequent change in the position of screw 353 changes the pressurewithin chamber 351, with a corresponding change in the force appliedbetween piston 344 and tool holder 335. In one embodiment, a surfacetreatment or surface coating 347 is applied to a surface of piston 344(as shown in FIG. 5), or alternately to the corresponding contactsurface of tool holder 335. In another embodiment, a surface treatmentor surface coating is applied against one or both of the angled surfacesof dovetail joint 337. The present invention contemplates creation of africtional force between any pair of surfaces contacting between body338 and tool holder 335, and/or adjusting means 340 and tool holder 335.

FIG. 6A shows a side elevational view of an apparatus 420 according toanother embodiment of the present invention. Apparatus 420 is a boringtool which includes a slidably adjustable cutting tool 425. Cutting tool425 is fixedly supported, such as by a tool support 430, which extendsfrom a slidably adjustable tool holder 435. Tool holder 435 preferablyincludes a joint 437 such as dovetail joint or T-joint which slidinglycouples to a complementary-shaped joint of a coupling element body 438.Coupling element body 438 is part of a coupling element 445. Couplingelement 445 preferably includes a conically-shaped end and a couplinginterface 446, both of which locate boring tool 420 in a drive unit suchas drive unit 88 of electronically controlled machine 82 (referring toFIG. 4).

Referring again to FIG. 6A, apparatus 420 includes a friction adjustmentapparatus 440 for clamping the sliding cutting tool to the boring toolwhich applies a normal force between facing contact surfaces ofapparatus 420, which can also be operated as means for actuating avariable friction force between a pair of contact surfaces, at least oneof the contact surface being on sliding tool holder 435. Actuating means440 includes a member 442 which displaces a plurality of springs 443 soas to urge member 444 toward tool holder 435. A surface treatment orsurface coating 447 applied to member 444 (as shown), or alternately tothe opposing face of tool holder 435, creates a frictional drag whichopposes lateral sliding movement of tool holder 435. Further, thepresent invention contemplates application of a surface treatment orsurface coating 447 to any pair of contact surfaces loaded incompression between tool holder 435 and body 438.

Actuating means 440 includes a cam 462 pivotally coupled to body 438,and also pivotally coupled to a linkage 463. Arranged on either end oflinkage 463 are moveable buttons 464 a and 464 b. As shown in FIG. 6A,actuating means 440 is in a first state in which button 464 b is in anoutward location, and cam 462 pivoted to a first position. Cam 462displaces member 442 by a first predetermined distance and therebyapplies a first predetermined force through springs 443 which create afirst contact force against sliding tool holder 435. This first contactforce creates a corresponding first frictional force which resistssliding motion of tool holder 435.

Actuation means 440 can also be actuated to a second state which resultsin a second predetermined frictional force between contact surfaces ofsliding tool holder 435 and either body 438 or actuating means 440.Actuating 440 can be placed in this second state by moving button 464 binward, which action causes linkage 463 to pivot cam 462 to a secondposition which further displaces member 442 and increases thecompression of springs 443. This additional compression of springsresults in a higher normal force of member 444 against tool holder 435.Actuation means 440 can be returned to the first state by inwardmovement of button 464 a. Actuation means 440 can be actuated to eitherthe first state or the second state by an operator using a tool toeither push or pull buttons 464 b or 464 a. Further, the presentinvention also contemplates those embodiments in which actuation means440 is actuated to either the first state or the second stateautomatically by a mechanism, such as a mechanism operably coupled tothe CNC boring machine. For example, a tool such as a rod can beattached to the boring machine or the table, with the controller of theboring machine placing apparatus 420 such that one of buttons 464 a or464 b are in contact with the rod. Subsequent lateral movement ofapparatus 420 will result in movement of the contacting button.

FIG. 6B depicts an apparatus 420′ substantially identical to apparatus420, but including features for direct coupling of a tool to cam 462′.Apparatus 420 b does not necessarily include the push buttons 464 a or464 b and does not necessarily include link 463 for actuation ofactuating means 440′. Apparatus 440′ includes an Allen head or relatedtorque-application feature coincident with pivot point 465 which permitsthe machine operator to directly pivot cam 462′. Access to the Allenhead of cam 462′ is provided through a bore (not shown) in body 438′.Thus, an operator can rotate cam 462′ with a tool to a first position orstate in which frictional forces restraining motion of tool holder 435can be overcome by an adjusting force laterally applied to tool holder435. After the position of cutting tool 425′ has been laterallyadjusted, the operator inserts the tool through the bore of body 435 toturn cam 462′ to a second position or state in which a higher frictionalforce restrains sliding motion of 435, the second higher level offrictional force being sufficient to withstand any lateral loads appliedduring machining. In addition, the present invention contemplates thoseembodiments in which cam 462′ is turned automatically by a mechanismsuch as a portion of the CNC machine, without the need for operatormanual access.

FIG. 7 shows a side elevational view of an apparatus 520 according toanother embodiment of the present invention. Apparatus 520 is a boringtool which includes a slidably adjustable cutting tool 525. Cutting tool525 is fixedly supported, such as by a tool support 530, which extendsfrom a slidably adjustable tool holder 535. Tool holder 535 preferablyincludes a joint 537 such as dovetail joint or T-joint which slidinglycouples to a complementary-shaped joint of a coupling element body 538.Coupling element body 538 is part of a coupling element 545. Couplingelement 545 preferably includes a conically-shaped end and a couplinginterface 546, both of which locate boring tool 520 in a drive unit suchas drive unit 88 of electronically controlled machine 82 (referring toFIG. 4).

Referring again to FIG. 7, apparatus 520 includes a friction adjustmentapparatus 540 for clamping the sliding cutting tool to the boring toolwhich applies a normal force between facing contact surfaces ofapparatus 520, which can also be operated as means 540 for actuating avariable frictional force. Actuating means 540 includes a piston 544slidable within a chamber 551. Pressure from a source such as ahydraulic pump (not shown) through hydraulic pressure port 554pressurizes the hydraulic fluid 552 within chamber 551. As one example,a hydraulic pump mounted to machine 82 provides hydraulic pressurethrough drive unit 88 into port 554 of coupling member 545.

Pressure of fluid 552 results in a corresponding force exerted by member544 upon sliding tool holder 535. This force exerted by member 544corresponds to a predetermined frictional force between opposingsurfaces of tool holder 535 and either body 538 and/or actuating means540. In one embodiment, actuating means 540 can be actuated to a firststate corresponding to first predetermined frictional force byapplication of a first hydraulic pressure within chamber 551. In anotherembodiment, actuating means 540 can also be actuated to a second statein which a second, higher pressure within chamber 551 results in acorrespondingly higher frictional force exerted against a contactsurface of tool holder 535 to resist sliding movement of tool holder 535relative to coupling member 545. In addition, the present inventioncontemplates those embodiments in which pressure is providedpneumatically by a gas such as compressed air.

FIG. 8 shows a side elevational view of an apparatus 620 according toanother embodiment of the present invention. Apparatus 620 is a boringtool which includes a slidably adjustable cutting tool 625. Cutting tool625 is fixedly supported, such as by a tool support 630, which extendsfrom a slidably adjustable tool holder 635. Tool holder 635 preferablyincludes a joint 637 such as dovetail joint or T-joint which slidinglycouples to a complementary-shaped joint of a coupling element body 638.Coupling element body 638 is part of a coupling element 645. Couplingelement 645 preferably includes a conically-shaped end and a couplinginterface 646, both of which locate boring tool 620 in a drive unit suchas drive unit 88 of electronically controlled machine 82 (referring toFIG. 4).

Referring again to FIG. 8, apparatus 620 includes a friction adjustmentapparatus 640 for clamping the sliding cutting tool to the boring toolwhich applies a normal force between facing contact surfaces ofapparatus 620, which can also be operated as actuating means forapplying a variable frictional force against sliding tool holder 635.Actuating means 640 includes a cam 662 pivotally coupled to body 638 andalso pivotally coupled in a slot to linkage 663. Linkage 663 is linearlyactuated by an electromagnetic solenoid 660 comprising a core andwindings. A pair of electrical conductors 665 provide electrical powerfrom a source (not shown) to actuate solenoid 660 between first andsecond states. As one example, electrical power is provided frommachining apparatus 82 through slip rings (not shown) of drive unit 88to conductors 665.

As shown in FIG. 8, solenoid 660 is in a first state, in which cam 662is in a first position to urge springs 643 against a member 644 tocreate a contact force against tool holder 635. Solenoid 663 can bechanged in state to transition link 663 upwards (as seen in FIG. 8) andthus pivot cam 662 to a second position in which springs 643 urge member644 against tool holder 635 with a second, higher contact force. Thissecond contact force results in a second, higher frictional forceapplied against tool holder 635 which restrains tool holder 635 fromlateral movement during machining.

In one embodiment, solenoid 660 is an electromagnetic solenoid with twopositions. As one example, solenoid 660 can be actuated by applicationof electrical voltage to a first state. Removal of the electricalvoltage results in the core of solenoid 660 transitioning to a secondstate by an internal spring load. In other embodiments, solenoid 660 isa two position latching electromagnetic solenoid, in which applicationof a first voltage moves the core of solenoid 660 to a first directionto a first position, and application of a reverse voltage moves the coreof solenoid 660 in an opposite direction to a second position. Further,the present application contemplates those embodiments in which the coreof the electromagnetic solenoid does not directly act upon the cam andlinkage of the actuating means, but instead acts upon a second stage,and the second stage provides the motive force necessary to pivot thecam. As one example, the second stage can be a hydraulically actuatedstage, in which case the first stage of solenoid 660 operates to actuatean electrohydraulic valve.

FIG. 9 shows a side elevational view of an apparatus 720 according toanother embodiment of the present invention. Apparatus 720 is a boringtool which includes a slidably adjustable cutting tool 725. Cutting tool725 is fixedly supported, such as by a tool support 730, which extendsfrom a slidably adjustable tool holder 735. Tool holder 735 preferablyincludes a joint 737 such as dovetail joint or T-joint which slidinglycouples to a complementary-shaped joint of a coupling element body 738.Coupling element body 738 is part of a coupling element 745. Couplingelement 745 preferably includes a conically-shaped end and a couplinginterface 746, both of which locate boring tool 720 in a drive unit suchas drive unit 88 of electronically controlled machine 82 (referring toFIG. 4).

Referring again to FIG. 9, apparatus 720 includes a friction adjustmentapparatus 740 for clamping the sliding cutting tool to the boring toolwhich applies a normal force between facing contact surfaces ofapparatus 720, which can also be operated as means for actuating avariable frictional force between contact surfaces of tool holder 735and either actuating means 740 or coupling body 738. Actuating means 740includes an electromagnet comprising a core member 744 and windings 764.Core member 744 is coupled at one end to an adjusting screw 741 whichcan adjust the distance between a face of core member 744 and anopposing face of sliding tool holder 735. As electrical power is appliedto conductors 765 from an electrical power source (not shown), voltageand windings 764 create a magnetic field with core member 744 thatattracts sliding tool holder 735. The force of attraction created by theelectromagnet results in a contact force between opposing surfaces oftool member 735 and body 738. These contact forces result in acorresponding frictional force which restrains tool member 735 fromsliding relative to body 738.

Actuating means 740 can be actuated to first and second states ofmagnetic attraction by corresponding application of first and secondelectrical currents through conductors 765. These first and secondmagnetic forces correspond to first and second levels of frictionalforce for restraining tool holder 735 from lateral movement. Further,some embodiments include application of a single amount of currentthrough conductors 765 so as to apply a single force between opposingcontact surfaces. Some embodiments of the present invention contemplatethe use of slip rings on the coupling element to provide electricalpower from an external source. Yet other embodiments contemplate the useof a battery placed within the boring tool to provide internalelectrical power.

Although what has been shown and described is an electromagnet formedfrom a separable body within body 738 of coupling 745, the presentinvention further contemplates the use of an electromagnet that isintegral to body 738, and which attracts at least a portion of toolholder 735 in a direction so as to create a frictional force on toolholder 735 that resists sliding motion. Further, the present inventionalso contemplates an electromagnet that is either separable or integralwith tool holder 735, and which attracts tool holder 735 toward body 738when energized. Those embodiments of the present invention usingelectromagnetic force to create the frictional force that resistssliding contemplate the use of magnetic materials in the construction ofthe boring tool, such as for the sliding tool holder or for the couplingmember. Further, the present invention contemplates those embodiments inwhich there are two electromagnets, including as a non-limiting example,a first electromagnet coupled to the tool holder and a secondelectromagnet coupled to the coupling member.

FIG. 10 shows a side elevational view of an apparatus 820 according toanother embodiment of the present invention. Apparatus 820 is a boringtool which includes a slidably adjustable cutting tool 825. Cutting tool825 is fixedly supported, such as by a tool support 830, which extendsfrom a slidably adjustable tool holder 835. Tool holder 835 preferablyincludes a joint 837 such as dovetail joint or T-joint which slidinglycouples to a complementary-shaped joint of a coupling element body 838.Coupling element body 838 is part of a coupling element 845. Couplingelement 845 preferably includes a conically-shaped end and a couplinginterface 846, both of which locate boring tool 820 in a drive unit suchas drive unit 88 of electronically controlled machine 82 (referring toFIG. 4).

Referring again to FIG. 10, apparatus 820 includes a friction adjustmentapparatus 840 for clamping the sliding cutting tool to the boring toolwhich applies a normal force between facing contact surfaces ofapparatus 820, and is also means 840 for actuating a variable forcebetween opposing contact surfaces of sliding tool holder 835 and eithercoupling body 838 or actuating means 840. Actuating means 840 preferablyincludes a plurality of centrifugal weights 864 which are pivotallycoupled by a pivot 865 to body 838. Actuating means 840 includes anadjusting screw 841 which applies a static load via spring 843 to member844. This static load from spring 843 applies a first contact forceagainst sliding tool holder 835 in a first, non-rotating state ofapparatus 820. This first state creates a frictional force against toolholder 835 sufficient to restrain tool holder 835 from any loose lateralmovement, but insufficient to restrain the lateral position of toolholder 835 when the lateral position of the tool holder is adjusted asdescribed herein.

Rotation of apparatus 820 actuates means 840 to a second state whichcorresponds to a second, higher contact force applied by member 844against sliding tool holder 835. As apparatus 820 rotates such as formachining an object, the more massive end of centrifugal weights 864 arethrown outwards, causing centrifugal weights 864 to pivot about pivot865. Preferably, centrifugal weights 864 include a cam-type shape, andthe pivoting actions of weights 864 cause the cam end to press againstmember 844 with a corresponding second, higher level of contact forceagainst tool holder 835.

FIGS. 12-15 depict various views of an apparatus 920 according toanother embodiment of the present invention. Apparatus 920 is a boringtool assembly which includes a slidably adjustable cutting tool 925.Cutting tool 925 is fixedly supported, such as by a tool support 930,which extends from a slidably adjustable tool holder 935. Tool holder935 preferably includes a joint 937 such as a dovetail joint or aT-joint which slidably couples to a complementary-shaped joint of acoupling element body 938. Coupling element 945 includes a couplingelement body 938, and locates boring tool 920 on a drive unit such asdrive unit 88 of machine 82 (referring to FIG. 4).

Boring tool 920 preferably includes a multiple piece tool holder 935which comprises a joint portion 937 coupled by a plurality of bolts 941to tool holding portion 935.1. Referring to FIGS. 12B and 14B, toolholding portion 935.1 of tool holder 935 includes a plurality of bores931 a, 931 b, and 931 c for receiving an inserted tool support 930. Aset screw (not shown) received within the appropriate threaded hole 918locks tool support 930 within the specific hole.

As best seen referring to FIGS. 12A, 13A, and 15A, joint portion 937 isslidingly received within a complementary-shaped portion of body 938. Asecond, tool-holding portion 935.1 is further slidingly received withina second complementary-shaped portion of body 938. Tool holder portions937 and 935.1 are fastened together by one or more fasteners 941, whichin one embodiment is an Allen head screw. Each fastener 941 is receivedwithin a counterbored hole 931 a, 931 b, and/or 931 c (as best seen inFIG. 12A and FIG. 14C). Referring to FIGS. 12A, 13A, and 13B, thethreaded end of the fastener is received within a counterbored well938.1 of body 938. As seen in FIG. 15B, joint portion 937 includes oneor more threaded holes 931 a′, 931 b′, and 931 c′ to accept the threadedportion of fasteners 941.

Referring to FIGS. 12A, 14A, and 15A, the sliding assembly of toolholder portions 935.1 and 937 within body 938 preferably leaves a smallgap between opposing faces 935.2 and 937.2. In those embodiments havingthis gap, tightening of fasteners 941 results in compression andfriction at two faces of body 938. Contact face 937 b of T-joint portion937 is placed in compressive contact with opposing face 938 b of body938 (see FIG. 13A). Further, contact surface 938 c is placed incompressive contact with contact face 935.1 c of tool holding portion935.1. Because of the aforementioned gap between opposing faces ofportions 937 and 935.1, these are two frictional interfaces forrestraining the lateral motion of tool holder 935.

Boring tool 920 can include various combinations of layers of frictionmaterials, surface coatings, and/or surface treatments so as to modifythe frictional forces at either the first pair of contact surfaces, 937b and 938 b, and/or the second pair of contact surfaces, 935.1 c and 938c. As one non-limiting example, a first friction treatment to increasefrictional forces can be applied at contact surfaces 938 c and/or 935.1c. A second type of frictional treatment to decrease the coefficient offriction can be applied at contact surfaces 937 b and/or 938 b. In thisembodiment, it is preferable to apply the lateral forces for adjustingthe position of cutting tool 925 at a contact point 921 a along asurface of tool holding portion 935.1, since portion 935.1 is moretightly held by friction than joint portion 937. However, the presentinvention also contemplates those embodiments in which the lateral forcefor adjusting the position of the cutting too is applied at a contactpoint 921 b along a surface of T-joint portion 937. The presentinvention also contemplates those embodiments in which the lateraladjusting force is applied simultaneously along surfaces of portions 937and 935.1.

FIGS. 16-19 depict various views of an apparatus 1020 according toanother embodiment of the present invention. Apparatus 1020 is a boringtool assembly which includes a slidably adjustable cutting tool 1025.Cutting tool 1025 is fixedly supported, such as by a tool support 1030,which extends from a slidably adjustable tool holder 1035. Tool holder1035 preferably includes a cylindrical joint 1037 which slidably couplesto a complementary-shaped joint of a coupling element body 1038.Coupling element 1045 includes a coupling element body 1038 locatesboring tool 1020 on a drive unit such as drive unit 88 of machine 82(referring to FIG. 4).

Boring tool 1020 preferably includes a multiple piece tool holder 1035which comprises a T-joint portion 1037 coupled by a plurality of bolts1041 to tool holding portion 1035.1. Referring to FIGS. 16B and 18B,tool holding portion 1035.1 of tool holder 1035 includes a plurality ofbores 1031 a, 1031 b, and 1031 c for receiving an inserted tool support1030. A set screw (not shown) received within the appropriate threadedhole 1018 locks tool support 1030 within the specific hole.

As best seen referring to FIGS. 16A, 17A, and 19A, joint portion 1037 isslidingly received within a complementary cylindrically shaped portionof body 1038. A second, tool-holding portion 1035.1 is further slidinglyreceived within a second complementary-shaped portion of body 1038. Toolholder portions 1037 and 1035.1 are fastened together by one or morefasteners 1041, which in one embodiment is an Allen head screw. Eachfastener 1041 is received within a counterbored hole 1031 a, 1031 b,and/or 1031 c (as best seen in FIG. 16A and FIG. 18C). Referring toFIGS. 16A, 17A, and 17B, the threaded end of the fastener is receivedwithin a counterbored well 1038.1 of body 1038. As seen in FIG. 19B,joint portion 1037 includes one or more threaded holes 1031 a′, 1031 b′,and 1031 c′ to accept the threaded portion of fasteners 1041.

Referring to FIGS. 16A, 18A, and 19A, the sliding assembly of toolholder portions 1035.1 and 1037 within body 1038 preferably leaves asmall gap between opposing faces 1035.2 and 1037.2. In those embodimentshaving this gap, tightening of fasteners 1041 results in compression andfriction at two faces of body 1038. Cylindrical contact face 1037 b ofjoint portion 1037 is placed in contact with opposing face 1038 b ofbody 1038 (see FIG. 17A). Further, contact surface 1038 c is placed incompressive contact with contact face 1035.1 c of tool holding portion1035.1. Because of the aforementioned gap between opposing faces ofportions 1037 and 1035.1, these are two frictional interfaces forrestraining the lateral motion of tool holder 1035.

Boring tool 1020 can include various combinations of layers of frictionmaterials, surface coatings, and/or surface treatments so as to modifythe frictional forces at either the first pair of contact surfaces, 1037b and 1038 b, and/or the second pair of contact surfaces, 1035.1 c and1038 c. As one non-limiting example, a first friction treatment toincrease frictional forces can be applied at contact surfaces 1038 cand/or 1035.1 c. A second type of frictional treatment to decrease thecoefficient of friction can be applied at contact surfaces 1037 b and/or1038 b. In this embodiment, it is preferable to apply the lateral forcesfor adjusting the position of cutting tool 1025 at a contact point 1021a along a surface of tool holding portion 1035.1, since portion 1035.1is more tightly held by friction than joint portion 1037. However, thepresent invention also contemplates those embodiments in which thelateral force for adjusting the position of the cutting too is appliedat a contact point 1021 b along a surface of joint portion 1037. Thepresent invention also contemplates those embodiments in which thelateral adjusting force is applied simultaneously along surfaces ofportions 1037 and 1035.1.

The embodiments of the present invention described and shown hereininclude a single cutting tool. However, it is understood that thepresent invention is not limited to embodiments with a single cuttingtool, and also contemplates those embodiments in which there aremultiple cutting tools on a single coupling element, including thoseembodiments in which there are multiple slidingly adjustable cuttingtools on a single coupling element.

Yet other embodiment of the present invention pertains to a slidablymovable cutting tool holder that machines a workpiece during thesliding. In one embodiment, the cutting tool holder includes a contouredexternal surface, the contour of which corresponds to the desired shapeof a hole or other feature to be machined into the workpiece. As theboring tool is advanced toward the object during machining, a staticmember in rolling or sliding contact with the cutting tool contouredsurfaces pushes the cutting tool holder so that the cutting toolmachines shape in the sidewall of the hole that corresponds to the shapeof the contoured surface. The cutting tool contoured surface acts as atemplate for the final shape of the sidewalls, and the static memberacts as a follower to the template.

FIGS. 20 and 21 depict apparatuses 1120 and 1220 respectively, forboring a hole with a contoured sidewall. As used herein the term“contoured sidewall” refers to sidewalls of a hole in which at least aportion of the sidewall has a surface which is not parallel to thecenterline of the hole. As non-limiting examples, contoured sidewallscan be conical, radiused, and/or S-shaped.

Boring tools 1120 and 1220 each include a cutting tool held within acutting tool holder that is slidably coupled to a body of a couplingelement. These boring tools include friction adjustment apparatus 1140and 1240, respectively, for clamping sliding cutting tool to the boringtool by applying a normal surface between facing contact surfaces, andwhich can also be operated as means for actuating a variable frictionforce, in the manner generally as previously shown and described herein.However, the friction adjustment apparatus is adjusted to provide africtional force which is sufficient to withstand any lateral forceapplied on the cutting tool holder by the machining forces applied tothe cutting tool, but insufficient to withstand the lateral forcesapplied by the static member against the cutting tool holder.

Apparatus 1120 and 1220 differ from the other boring tools describedherein by having an external contoured surface on the slidable cuttingtool holder. As seen best in FIG. 20, boring tool 1120 includes anangled external surface 1134 which corresponds to a desired bevel angleto be machined into a hole of a workpiece. Referring to FIG. 21, boringtool 1220 includes a cutting tool holder 1235 with a contoured surface1234 which includes a plurality of external angled surfaces, and also acentral straight portion there between. Preferably, template surfaces1134 and 1234 are hardened such as by heat treating and/or coating.Further, these contoured surfaces can be coated with a material thatreduces sliding or rolling friction.

FIG. 22 schematically depicts a system 1180 according to anotherembodiment of the present invention. System 1180 preferably includes anelectronically controlled machine (such as a CNC boring machine 1182) aspreviously described. As is well known in the art, boring machine 1182advances boring tool 1120 along axis 1122 so as to machine workpiece1186. However, the present invention also includes those embodiments inwhich table 1192 is moved axially toward the boring tool, which rotatesbut does not move axially.

System 1180 includes a static member 1150 which is preferably ridged andfixedly mounted to machine 1182. Thus, static member 1150 preferablydoes not move either axially or laterally as boring tool 1120 rotatesand moves axially. However, in those embodiments in which table 1192move axially toward the boring tool, static member 1150 is rigidly andfixedly mounted to either table 1192 or workpiece 1186.

Static member 1150 includes a projecting follower 1156 a whichpreferably includes at its end in antifriction bearing 1156 b, such as aball bearing. Antifriction bearing 1156 b is captured within a socket offollower 1156 a, and is free to rotate within that socket.

Static member 1150 is located proximate boring tool 1120, such thatbearing 1156 b of follower 1156 a is in contact with contoured surface1134 of boring tool 1120. Bearing 1156 b presses against contouredsurface 1134. As boring tool 1120 is advanced forward along axis 1122toward workpiece 1186, bearing 1156 b presses against contoured surface1134, and slides cutting tool 1135 relative to boring tool 1120 by thispressing. Since boring tool 1120 is being rotated by drive unit 1188during this axial advancement, the resulting hole machined intoworkpiece 1186 includes a sidewall 1184 a which includes a contour thatcorresponds to the contour of surface 1134.

As best seen in FIG. 22, bearing 1156 b presses against that portion ofsurface 1144 which is furthest away from rotational centerline 1122.Thus, the pressing of bearing 1156 b against surface 1134 occurs onceper revolution of boring tool 1120. Since cutting tool 1125 is locatedon that part of cutting tool holder 1135 which is also furthest awayfrom centerline 1122, the sidewall 1184 a of hole 1184 correspondsdirectly to the shape of contoured surface 1134.

In contrast, FIG. 23 depicts a system 1180′ for boring a hole such thatthe shape of the sidewalls corresponds to the inverse of the contouredsurface of the cutting tool holder. In this embodiment, tool support1130′ is placed on the side of centerline 1122 that is opposite to theside of cutting tool holder 1135′ which extends furthest from centerline1122. As shown in FIG. 2523, advancement of boring tool 1120′ towardworkpiece 1186′ results in cutting tool 1125′ machining a larger holediameter as the advancement occurs because of the lateral movement oftool holder 1135. Therefore, contour 1184 a′ of hole 1184′ correspondsto an inverted shape of contact surface 1134′.

In yet another embodiment of the present invention, the contouredsurface corresponding to the desired shape of the hole contouredsidewall is placed on the static member, and the surface follower islocated on the rotating boring tool. FIGS. 24 and 25 depict an apparatus1420 for boring a hole with a contoured sidewall.

Boring apparatus 1420 includes the cutting tool, tool support, slidablecutting tool holder, coupling element, and coupling element body aspreviously described. Further, boring apparatus 1420 includes a frictionadjustment apparatus 1440 for clamping the sliding cutting tool to theboring tool which applies a normal force between facing contactsurfaces, and which can also be operated as actuating means for applyinga variable friction force. However, the friction adjustment apparatus isadjusted to provide a frictional force which is sufficient to withstandany lateral force applied on the cutting tool holder by the machiningforces applied to the cutting tool, but insufficient to withstand thelateral forces applied by the static member against the cutting toolholder.

Slidable cutting tool holder 1435 also includes on its outer surface afollower assembly comprising a projecting follower 1457 a whichpreferably includes an antifriction bearing 1457 b. Preferablyantifriction bearing 1457 b is a ball bearing retained in a socket offollower 1457 a, and is free to rotate within the socket. As best seenin FIG. 25, follower 1457 a and antifriction bearing 1457 b arepreferably located 180° opposite of cutting tool 1425. Any force appliedagainst bearing 1457 b thus tends to radially oppose a component of themachining forces applied to cutting tool 1425.

FIG. 26 schematically depicts a system 1280 according to anotherembodiment of the present invention. System 1280 preferably includes anelectronically controlled machine (such as a CNC boring machine 1282) aspreviously described. As is well known in the art, boring machine 1282advances boring tool 1220 along axis 1222 so as to machine workpiece1286. However, the present invention also includes those embodiments inwhich table 1292 is moved axially toward the boring tool, which rotatesbut does not move axially.

System 1480 preferably includes a static member 1450 which is rigidlymounted to either table 1492, workpiece 1486, or for those embodimentsin which the cutting tool is advanced along its central axis, tomachining apparatus 1482. As shown in FIG. 26, static member 1450includes a contoured surface 1458 which corresponds to a desired shapein the sidewalls 1484 a of hole 1484. Bearing 1457 b of boring tool 1420is in rolling contact with contoured surface 1458. As boring tool 1420is advanced along axis 1422 toward workpiece 1480, static member 1450exerts a lateral force on cutting tool holder 1435 which slides toolholder 1435. As depicted in FIG. 26, tool support 1430 is located on theside of centerline 1422 that is opposite to the most radially outwardportion of cutting tool holder 1435, and therefore the machined sidewall1484 a corresponds to the inverse of contoured surface 1458. It isunderstood that the present invention contemplates location of toolsupport 1430 anywhere on tool holder 1435.

FIG. 27 illustrates a cross sectional view of FIG. 26. It can be seenthat contoured surface 1488 preferably has a circular shape in a planeperpendicular to axis 1422.

FIG. 28 illustrates a schematic representation of a system 1480′ forboring a hole with a contoured sidewall. System 1480′ is the same assystem 1480 previously described, except for differences in the staticmember and contoured surface which will now be described.

System 1480′ includes a static member 1450′ which generally surrounds aportion of boring tool 1420. Static member 1450′ includes supportmembers 1450 a′ which couple a ring 1450 b′ to machining apparatus 1482.In other embodiments of the present invention, static member 1450′ canbe fixedly attached to either table 1492 or workpiece 1486.

Ring 1450 b′ includes a contoured inner surface 1458′ which generallysurrounds a portion of boring tool 1420. As boring tool 1420 is advancedalong axis 1422 toward workpiece 1486, static member 1450′ applies alateral load to bearing 1457 b which slides cutting tool holder 1435during machining. This combined action of axial relative movement andlateral shifting results in a hole whose sidewalls correspond to theshape of contoured surface 1458′.

FIG. 29 is a cross sectional view of some of the apparatuses of FIG. 28.As previously discussed, ring 1450 b′ generally surrounds a portion ofcutting tool 1420. As cutting tool 1420 rotates about axis 1422, bearing1457 b is in continuous contact with inner surface 1458′. Therefore, ascutting tool 1420 advances toward the workpiece, the radially inwardload applied to bearing 1457 b is applied throughout each revolution, incontrast to member 1450 (as seen in FIG. 27) where the radially inwardforce applied to cutting tool 1435 is applied over a portion of eachrevolution.

FIGS. 30-34 depict various views of an apparatus 1520 according toanother embodiment of the present invention. Apparatus 1520 is a boringtool assembly which includes a slidably adjustable cutting tool 1525.Cutting tool 1525 is fixedly supported, such as by a tool support 1530,which extends from a slidably adjustable tool holder 1535. Tool holder1535 preferably includes a joint 1537 such as a dovetail joint or aT-joint which slidably couples within a complementary-shaped jointformed by pocket 1538.3 and underside surface 1570 b of retention member1570. Coupling element 1545 includes a coupling element body 1538, andlocates boring tool assembly 1520 on a drive unit such as drive unit 88of machine 82 (referring to FIG. 4). Coupling element 1545 couples toolholder 1535 to the boring machine. Coupling element 1545 is slidable ina direction relative to tool holder 1535. Tool holder 1535 is adjustableover a range of positions in the direction for machining a hole within arange of dimensions that correspond to the range of positions.

Boring tool 1520 preferably includes a multiple piece tool holder 1535which comprises a joint portion 1537. Referring to FIG. 32B, toolholding portion 1535.1 of tool holder 1535 includes a plurality of bores1531 a, 1531 b, and 1531 c for receiving an inserted tool support 1530.A set screw (not shown) received within the appropriate threaded hole1518 locks tool support 1530 within the specific hole.

Referring to FIGS. 30A and 30B, tool holder 1535 is slidably capturedwithin the assembly of coupling element 1545, as will be described.Coupling element 1545 includes a body 1538 which includes at least onespring pocket 1538.1, and preferably includes a plurality of springpockets. In one embodiment, spring pocket 1538.1 accepts therein abiasing member 1543. As shown in FIG. 30A, in one embodiment, biasingmember 1543 is a coil spring. However, the present inventioncontemplates other types of biasing members, including, for example,pneumatically or hydraulically actuated expandable pressure vessels,coil springs, and leaf springs.

Preferably, each spring 1543 has a height that is greater than the depthof the corresponding pocket 1538.1. With this arrangement, each springwill “stand proud” when placed within the corresponding pocket. Locatedon top of the top end of springs 1543 is a movable plate member 1544.Spring forces bias movable member 1544 away from pockets 1538.1. Movablemember 1544 preferably resides within a complementary-shaped pocket1538.2. This pocket accepts the external shape of movable member 1544(as best seen in FIG. 34A), and is preferably close fitting. However,the present invention also contemplates those embodiments in whichmovable member 1544 is located within a non-complementary shaped pocketthat is not close fitting. Movable member 1544 preferably has a heightthat is less than the depth of pocket 1538.2.

Although what has been shown and described is an arrangement in whichthe springs have an end that extends beyond the top of the correspondingpocket, the present invention also contemplates those embodiments inwhich the springs are equal in height to the pocket, or lesser inheight. In some of these embodiments, movable member 1544 includes acorresponding spacer portion that fits within the spring pocket andcontacts the top of the spring.

Tool holder 1535 includes a sliding joint portion 1537 that fits withina pocket 1538.3 of body 1538. Joint 1537 has a height 1537.1 that ispreferably less than the depth of pocket 1538.3. Tool holder 1535includes a contact surface 1537 a which is in contact with surface 1544a of movable member 1544. Preferably, surface 1544 a includes a surfacetreatment or coating that provides a controlled coefficient of frictionwith surface 1537 a. However, the present invention also contemplatesthose embodiments in which both surfaces 1544 a and 1537 a include asurface coating or surface treatment, and also those embodiments inwhich only surface 1537 a includes a surface coating or surfacetreatment. Boring tool assembly 1520 includes means for applying africtional force between contact surfaces including springs 1543 andmovable member 1544.

Tool holder 1535 preferably includes a scalloped recess 1571 whichslidably receives the retention ears 1572 of members 1570. A pair ofretention members 1570 are received within recess 1571 and fastened tobody 1538. Members 1570 compress the assembly of springs 1543, movablemember 1544, and joint portion 1537 of holder 1535. Fasteners 1541 arepreferably tightened until the underside surface 1570 b of retention1570 is in contact with body 1538. Since the height of joint portion1537 is less than the depth of pocket 1538 and further that thethickness of movable member 1544 is less than the depth of pocket1538.2, the tightening of fasteners 1541 results in a compression ofmovable member 1544 against springs 1543. In one embodiment, there aresix springs 1543, and each is compressed about 0.1 inches in thisassembled condition. These six springs preferably provide from about 10to 100 pounds of force per spring against movable member 1544. Biasingmembers 1543 apply a compression force between contact surfaces 1544 aand 1537 a to increase the frictional force between those same twocontact surfaces, such that sliding movement of tool holder 1535relative to coupling member 1545 is restrained.

As will be appreciated from FIG. 30A, there is also a frictionalinterface between surface 1537 b of tool holder 1535 and surface 1570 bof retention members 1570. These facing surfaces are maintained incompression by springs 1543. The present invention contemplates thoseembodiments in which one or both of surfaces 1537 b and 1570 b alsoinclude coatings or treatments for control of the coefficient offriction therebetween.

Further, although what has been shown and described is a movable memberurged by a biasing member against the bottom of the tool holder, thepresent invention also contemplates those embodiments in which thebiasing members act directly against a surface of the sliding toolholder. In such embodiments, the biasing members act directly on thesliding tool holder, and the friction between the sliding tool holderand a retention member restrains lateral sliding of the tool holder.

Some embodiments of the present invention can include a small amount of“positional hysteresis” which affects the manner in which a slidablyadjustable tool holder is moved to a position for boring a hole. Forexample, with regards to certain embodiments of the present invention,when the slidably adjustable tool holder is moved to a position forboring a hole, some components of the boring tool assembly retain asmall stress or “memory” which can attempt to move the slidable toolholder back towards the position from which it came. For example,referring to FIG. 12A, boring tool 920 includes two slidable tool holderportions 935.1 and 937. As a lateral force is applied against toolholder portion 935.1, portion 937 within body 938 also slides in thesame direction. The lateral force is present until portion 935.1 hasmoved to a new location. Once the lateral force is removed, portion935.1 remains at the new position, held in place by frictional forces.

However, in some embodiments, tool holder portion 937 does not movelaterally as much as portion 935.1, and therefore exerts a small lateralrestoring force through fastener 941 which urges portion 935.1 away fromits new position and back towards its original position. Although thefrictional force maintaining portion 935.1 in its new location issufficient to retain it in the desired position under many conditions,it is possible that a vibratory load or other load imposed duringmachining can cause portion 935 to move slightly as result of the“returning” force or “memory” force exerted by portion 937 and fastener941. In some embodiments of the present invention, it is believed thatthis “returning” force is negligible. In other embodiments, the amountof returning lateral movement caused by this returning force can beaccounted for in the control algorithm of the CNC boring machine.However, in other embodiments of the present invention, the boring toolassembly includes certain features that minimize and/or eliminate thismechanical hysteresis. FIGS. 35-41 depict various embodimentsincorporating a variety of features which relate to the positional“hysteresis” or accuracy of methods, systems, and apparatus pertainingto slidably adjustable tool holders for a boring machine. It isunderstood that the various features described in these figures areapplicable to many of the various embodiments described herein.

FIG. 35 is a schematic representation of another embodiment according tothe present invention, shown in sectional view through the centerline ofthe apparatus. Apparatus 1620 is a boring tool assembly which includes aslidably adjustable cutting tool 1625. Cutting tool 1625 is fixedlysupported by a tool support 1630, which extends from a slidablyadjustable tool holder 1635. Preferably, apparatus 1625 further includesa coupling element 1645 which includes a coupling element body 1638, aswell as various internal components which will be described. Tool holder1635 is slidably retained on coupling member 1645, preferably by aretention member 1670. Retention member 1670 permits sliding of toolholder 1635 in a direction permitting cutting tool 1625 to bore avariety of hole diameters or other features. As one example, referringto FIG. 35, the direction is sideways.

Boring tool assembly 1620 includes an internal frictional adjustmentapparatus 1640 which includes a movable member 1644 preferably includinga surface treatment or surface coating 1647 for controlling slidingfriction and one or more biasing members 1643 which preferably providean elastic biasing force. As used herein the term elastic refers to theability of the biasing member to provide a resisting force when thebiasing member is placed in compression, tension, torsion and/or shear,such that the member returns to a shape without permanent deformationwhen the compressing tension, torsion, or shear is removed. For sake ofclarity, FIG. 35 includes a single biasing member 1643, but it isappreciated that various embodiments of the present inventioncontemplate multiple biasing members. Further, although the variousfigures herein depict a particular type of biasing member, such as acoil spring, it is further appreciated that other embodiments of thepresent invention include any of the biasing members noted herein,including by way of example centrifugal apparatus, hydraulic orpneumatic pressure mechanisms, magnets, as well as others. And furtherwith the biasing members adapted and configured either to urge apart thetool holder from the coupling member, or to urge together the toolholder and a coupling member. Further, biasing members depicted ordescribed as coil springs can be any type of spring, includingtorsional, leaf, belleville, and others.

Movable member 1644 is preferably closely fitting within a pocket orbore 1638.2 of body 1638. Because of the close-fitting nature of member1644 within bore 1638.2, any side to side motion of member 1644 isgreatly reduced. However, to further minimize any lateral motion ofmember 1644, a surface coating 1647.2 is applied to the sides of member1644. Surface coating or treatment 1647.2 can be any of the coatings ortreatment previously described, although preferably the selected coatingor treatment minimizes the sliding friction between member 1644 and thecontacting walls of pocket 1638.2. As one example, the surface coatingcould be an organic material such as Teflon®, nylon, or other organicmaterial with low friction and good wear properties. Further, thesurface coating or treatment 1647.2 can be a build up of abradablematerial, a portion of which is worn-off during initial insertion ofmember 1644 within bore 1638.2. Further, the idea of “surface coating ortreatment” as described herein includes the attachment of material tothe sides of member 1644, such as by riveting, welding, brazing, use ofadhesives, or other methods.

FIG. 36 is a schematic representation of another embodiment according tothe present invention, shown in sectional view through the centerline ofthe apparatus. Apparatus 1720 is a boring tool assembly which includes aslidably adjustable cutting tool 1725. Cutting tool 1725 is fixedlysupported by a tool support 1730, which extends from a slidablyadjustable tool holder 1735. Preferably, apparatus 1725 further includesa coupling element 1745 which includes a coupling element body 1738, aswell as various internal components which will be described. Tool holder1735 is slidably retained on coupling member 1745, preferably by aretention member 1770. Retention member 1770 permits sliding of toolholder 1735 in a direction permitting cutting tool 1725 to bore avariety of hole diameters or other features. As one example, referringto FIG. 36, the direction is sideways.

Boring tool assembly 1720 includes an internal frictional adjustmentapparatus 1740 which includes a movable member 1744 preferably includinga surface treatment or surface coating 1747 for controlling slidingfriction and one or more biasing members 1743 which preferably providean elastic biasing force. As used herein the term elastic refers to theability of the biasing member to provide a resisting force when thebiasing member is placed in compression, tension, torsion and/or shear,such that the member returns to a shape without permanent deformationwhen the compressing tension, torsion, or shear is removed. For sake ofclarity, FIG. 36 includes a single biasing member 1743, but it isappreciated that various embodiments of the present inventioncontemplate multiple biasing members.

Movable member 1744 is guided within body 1738 of coupling element 1745in a second direction that is at least partly orthogonal to thedirection of sliding. Further, biasing member 1743 applies a forcebetween body 1738 and movable member 1744 that urges movable member 1744at least partly in the second direction. As will now be discussed,movable member 1744 is substantially restrained from motion in thedirection of sliding.

Movable member 1744 is preferably closely fitting within a pocket orbore 1738.2 of body 1738. Because of the close-fitting nature of member1744 within bore 1738.2, any side to side motion of member 1744 isgreatly reduced. However, to further minimize any lateral motion ofmember 1744, a surface coating 1747.2 is applied to the sides of bore1738.2. Surface coating or treatment 1747.2 can be any of the coatingsor treatment previously described, although preferably the selectedcoating or treatment minimizes the sliding friction between member 1744and walls of pocket 1738.2. As one example, the surface coating could bean organic material such as Teflon®, nylon, or other organic materialwith low friction and good wear properties. Further, the surface coatingor treatment 1747.2 can be a build up of abradable material, a portionof which is worn-off during initial insertion of member 1744 within bore1738.2. Further, the idea of “surface coating or treatment” as describedherein includes the attachment of material to the sides of member 1744,such as by riveting, welding, brazing, use of adhesives, or othermethods.

FIG. 37 is a schematic representation of another embodiment according tothe present invention, shown in sectional view through the centerline ofthe apparatus. Apparatus 1820 is a boring tool assembly which includes aslidably adjustable cutting tool 1825. Cutting tool 1825 is fixedlysupported by a tool support 1830, which extends from a slidablyadjustable tool holder 1835. Preferably, apparatus 1825 further includesa coupling element 1845 which includes a coupling element body 1838, aswell as various internal components which will be described. Tool holder1835 is slidably retained on coupling member 1845, preferably by aretention member 1870. Retention member 1870 permits sliding of toolholder 1835 in a direction permitting cutting tool 1825 to bore avariety of hole diameters or other features. As one example, referringto FIG. 37, the direction is sideways.

Boring tool assembly 1820 includes an internal frictional adjustmentapparatus 1840 which includes a movable member 1844 preferably includinga surface treatment or surface coating 1847 for controlling slidingfriction and one or more biasing members 1843 which preferably providean elastic biasing force. For sake of clarity, FIG. 37 includes a singlebiasing member 1843, but it is appreciated that various embodiments ofthe present invention contemplate multiple biasing members.

Movable member 1844 is guided within body 1838 of coupling element 1845in a second direction that is at least partly orthogonal to thedirection of sliding. Further, biasing member 1843 applies a forcebetween body 1838 and movable member 1844 that urges movable member 1844at least partly in the second direction. As will now be discussed,movable member 1844 is substantially restrained from motion in thedirection of sliding.

Movable member 1844 is received preferably loosely received within apocket 1838.2 of body 1838. However, in order to minimize the side toside motion of movable member 1844, member 1844 includes one or moreguiding features 1844.4 which are received within one or morecorresponding close-fitting complementary-shaped features or bores1838.4. The acceptance of a guiding feature 1844.4 within acomplementary-shaped feature 1838.4 restrains movable member 1844 fromside to side motion. In some embodiments of the present invention, oneor both of the guiding features 1844.4 and 1838.4 include surfacecoating or treating as previously described, preferably for minimizingsliding friction. In one embodiment, guiding features 1844.4 are a pairof dowel rods coupled to movable member 1844, and thecomplementary-shaped guiding feature 1838.4 is a hole or bore having thesame external shape as the dowel rod.

FIG. 38 is a schematic representation of another embodiment according tothe present invention, shown in sectional view through the centerline ofthe apparatus. Apparatus 1920 is a boring tool assembly which includes aslidably adjustable cutting tool 1925. Cutting tool 1925 is fixedlysupported by a tool support 1930, which extends from a slidablyadjustable tool holder 1935. Preferably, apparatus 1925 further includesa coupling element 1945 which includes a coupling element body 1938, aswell as various internal components which will be described. Tool holder1935 is slidably retained on coupling member 1945, preferably by aretention member 1970. Retention member 1970 permits sliding of toolholder 1935 in a direction permitting cutting tool 1925 to bore avariety of hole diameters or other features. As one example, referringto FIG. 38, the direction is sideways.

Boring tool assembly 1920 includes an internal frictional adjustmentapparatus 1940 which includes a movable member 1944 preferably includinga surface treatment or surface coating 1947 for controlling slidingfriction and one or more biasing members 1943 which preferably providean elastic biasing force. For sake of clarity, FIG. 38 includes a singlebiasing member 1943, but it is appreciated that various embodiments ofthe present invention contemplate multiple biasing members.

Movable member 1944 is guided within body 1938 of coupling element 1945in a second direction that is at least partly orthogonal to thedirection of sliding. Further, biasing member 1943 applies a forcebetween body 1938 and movable member 1944 that urges movable member 1944at least partly in the second direction. As will now be discussed,movable member 1944 is substantially restrained from motion in thedirection of sliding.

Movable member 1944 is bearingly guided within a pocket 1938.2 of body1938. An assembly of roller bearings 1973 is preferably located onopposing sides of pocket 1938.2, and reduces any frictional force whichopposes the urging force from biasing member 1943.

To reduce the lateral motion of member 1944, preferably at least one ofthe bearing assemblies 1973 is biased laterally by a spring member 1972.In one embodiment, biasing member 1972 urges a bearing assembly 1973toward the opposite bearing assembly 1973, such that in the unassembledstate, the distance between bearing assemblies is less than the width ofmovable member 1944. Insertion of member 1944 between the opposingbearing assemblies 1973 results in lateral movement of the spring loadedbearing assembly and compression of spring 1972. When assembled againstat least one spring loaded bearing assembly, movable member 1944 doesnot move laterally unless the lateral force is sufficient to overcomethe spring force exerted by spring 1972. Spring 1972 is adapted andconfigured to urge against movable member 1944 with a lateral force thatis preferably greater than the lateral force for adjustment of toolholder 1935.

In yet other embodiments of the present invention, there are bearingassemblies on opposing sides of movable member 1944, with only one sidebeing spring loaded. In some of those embodiments, the non-spring loadedbearing is located on a side of movable member 1944 such that movementof tool holder 1935 in a direction to increase the size of a hole boredby cutting tool 1925 slides movable member 1944 toward the non-springloaded bearing.

FIG. 39 is a schematic representation of another embodiment according tothe present invention, shown in sectional view through the centerline ofthe apparatus. Apparatus 2020 is a boring tool assembly which includes aslidably adjustable cutting tool 2025. Cutting tool 2025 is fixedlysupported by a tool support 2030, which extends from a slidablyadjustable tool holder 2035. Preferably, apparatus 2025 further includesa coupling element 2045 which includes a coupling element body 2038, aswell as various internal components which will be described. Tool holder2035 is slidably retained on coupling member 2045, preferably by aretention member 2070. Retention member 2070 permits sliding of toolholder 2035 in a direction permitting cutting tool 2025 to bore avariety of hole diameters or other features. As one example, referringto FIG. 39, the direction is sideways.

Boring tool assembly 2020 includes an internal frictional adjustmentapparatus 2040 which includes a movable member 2044 preferably includinga surface treatment or surface coating 2047 for controlling slidingfriction and one or more biasing members 2043 which preferably providean elastic biasing force. For sake of clarity, FIG. 39 includes a singlebiasing member 2043, but it is appreciated that various embodiments ofthe present invention contemplate multiple biasing members.

Movable member 2044 is guided within body 2038 of coupling element 2045in a second direction that is at least partly orthogonal to thedirection of sliding. Further, biasing member 2043 applies a forcebetween body 2038 and movable member 2044 that urges movable member 2044at least partly in the second direction. As will now be discussed,movable member 2044 is substantially restrained from motion in thedirection of sliding.

Frictional adjustment apparatus 2040 of boring tool 2020 preferablyincludes biasing members 2043 and movable member 2044 which are adaptedand configured such that the force from biasing members 2043 urgemovable member 2044 parallel to the direction of sliding and also in asecond direction that is at least partly orthogonal to the direction ofsliding. In one embodiment, springs 2043 are located within pockets2038.1 such that the springs act in a direction with a directionalcomponent that is parallel to the direction of the sliding of toolholder 2035.

As shown in FIG. 39, springs 2043 act laterally. Each biasing member2043 preferably acts upon an intermediate sliding member 2074. Eachintermediate member 2074 preferably includes an angled surface incontact with a complementary-shaped surface 2044.2 of movable member2044. As shown in the particular embodiment of FIG. 39, the angledsurfaces of intermediate members 2074 are angled at approximately 45degrees relative to the centerline 2022 of apparatus 2020. Therefore,the forces from biasing members 2043 act upon movable member 2044 in adirection parallel to the direction of sliding and also orthogonal tothe direction of sliding. Therefore, any lateral motion imparted tomovable member 2044 by sliding adjustment of tool holder 2035 isresisted by at least one of the biasing members 2043. Further, biasingmembers 2043 are effective in applying a normal force between movablemember 2044 and tool holder 2035 that imparts a frictional forcesufficient to restrain lateral motion of tool holder 2035 duringmachining.

FIG. 40 is a schematic representation of another embodiment according tothe present invention, shown in sectional view through the centerline ofthe apparatus. Apparatus 2120 is a boring tool assembly which includes aslidably adjustable cutting tool 2125. Cutting tool 2125 is fixedlysupported by a tool support 2130, which extends from a slidablyadjustable tool holder 2135. Preferably, apparatus 2125 further includesa coupling element 2145 which includes a coupling element body 2138, aswell as various internal components which will be described. Tool holder2135 is slidably retained on coupling member 2145, preferably by aretention member 2170. Retention member 2170 permits sliding of toolholder 2135 in a direction permitting cutting tool 2125 to bore avariety of hole diameters or other features. As one example, referringto FIG. 40, the direction is sideways.

Boring tool assembly 2120 includes an internal frictional adjustmentapparatus 2140 which includes a movable member 2144 preferably includinga surface treatment or surface coating 2147 for controlling slidingfriction and one or more biasing members 2143 which preferably providean elastic biasing force. For sake of clarity, FIG. 40 includes a singlebiasing member 2143, but it is appreciated that various embodiments ofthe present invention contemplate multiple biasing members.

Movable member 2144 is guided within body 2138 of coupling element 2145in a second direction that is at least partly orthogonal to thedirection of sliding. Further, biasing member 2143 applies a forcebetween body 2138 and movable member 2144 that urges movable member 2144at least partly in the second direction. Movable member 2144 issubstantially restrained from motion in the direction of sliding.Movable member 2144 includes a coating 2147.2 on the sides of themovable member that maintain a close fit within bore 2138.2.

Boring tool apparatus 2120 is the same as apparatus 1620 except thatthere is an assembly of roller bearing 2143.1 interposed between spring2143 and movable member 2144 that transmit the biasing force from member2143 to member 2144. Roller bearings 2143.1 minimize any “restoring”lateral force imparted by biasing member 2143 upon movable member 2144.

FIG. 41 is a schematic representation of another embodiment according tothe present invention, shown in sectional view through the centerline ofthe apparatus. Apparatus 2220 is a boring tool assembly which includes aslidably adjustable cutting tool 2225. Cutting tool 2225 is fixedlysupported by a tool support 2230, which extends from a slidablyadjustable tool holder 2235. Preferably, apparatus 2225 further includesa coupling element 2245 which includes a coupling element body 2238, aswell as various internal components which will be described. Tool holder2235 is slidably retained on coupling member 2245, preferably by aretention member 2270. Retention member 2270 permits sliding of toolholder 2235 in a direction permitting cutting tool 2225 to bore avariety of hole diameters or other features. As one example, referringto FIG. 41, the direction is sideways.

Boring tool assembly 2220 includes an internal frictional adjustmentapparatus 2240 which includes a movable member 2244, and one or morebiasing members 2243 which preferably provide an elastic biasing force.For sake of clarity, FIG. 41 includes a single biasing member 2243, butit is appreciated that various embodiments of the present inventioncontemplate multiple biasing members and other types of biasing members.

Movable member 2244 is guided within body 2238 of coupling element 2245in a second direction that is at least partly orthogonal to thedirection of sliding. Further, biasing member 2243 applies a forcebetween body 2238 and movable member 2244 that urges movable member 2244at least partly in the second direction. As will now be discussed,movable member 2244 is substantially restrained from motion in thedirection of sliding.

Boring tool apparatus 2220 includes an internal frictional adjustmentapparatus 2240 in which the frictional force restraining the movement oftool holder 2235 during machining is applied between surface 2237 b ofjoint 2237 and surface 2270 b of retention member 2270. Preferably,either or both surfaces 2237 b and 2270 b include a surface coating ortreatment 2275 which provides for a controlled frictional interfacebetween slidable tool holder 2235 and retention member 2270 of couplingelement 2245. The normal force which provides the aforementionedfrictional force comes from a biasing member 2243 which acts on amovable member 2244. An assembly of roller bearings 2243.1 placedbetween movable member 2244 and the opposing surface of joint 2237reduces any lateral forces between member 2244 and joint 2237. Thepresent invention also contemplates those embodiments in which a forcefrom the biasing member acts directly upon tool holder 2235.

FIG. 42 is a schematic representation of another embodiment 1520′,similar except as described and depicted to apparatus 1520, and shown insectional view through the centerline of the apparatus. Apparatus 1520′is a boring tool assembly which includes a slidably adjustable cuttingtool 1520′. Cutting tool 1525′ is fixedly supported by a tool support1530′, which extends from a slidably adjustable tool holder 1535′.Preferably, apparatus 1525′ further includes a coupling element 1545′which includes a coupling element body 1538′, as well as variousinternal components which will be described. Although variousembodiments shown herein depict various components of the couplingelement or the tool support, the present invention also contemplatesthose alternate embodiments in which these same or equivalent componentsare included in the other one of the coupling element or tool holder.Tool holder 1535′ is slidably retained on coupling member 1545′,preferably by a retention member 1570′. Retention member 1570′ permitssliding of tool holder 1535′ in a direction permitting cutting tool1525′ to bore a variety of hole diameters or other features. As oneexample, referring to FIG. 42, the direction is sideways.

Boring tool assembly 1520′ includes an internal frictional adjustmentapparatus 1540′ which includes a tool holder 1535′, a surface treatmentor surface coating 1547′ on either tool holder 1535′ and/or body 1538′for controlling sliding and static friction, and one or more biasingmembers 1543′ which preferably provide an elastic biasing force.

Tool holder 1535′ is located within body 1538′ of coupling element 1545′in a second direction that is at least partly orthogonal to thedirection of sliding. Further, biasing members 1543′ apply a forcebetween body 1538′ and tool holder 1535′ that urges tool holder 1535′ atleast partly in the second direction.

One difference between apparatus 1520 and 1520′ relates to the directionof biasing force applied by biasing members 1543 and 1543′. Referringbriefly to FIG. 30A, springs 1543 are adapted and configured to pushapart coupling element 1545 and sliding tool holder 1535. Biasingelements 1543 urge cutting tool 1525 toward the object being machined.In contrast, tool holder 1535′ of apparatus 1520′ is adapted andconfigured so that springs 1543′ urge tool holder 1535′ toward couplingelement 1545′. The arrangement and configuration of springs 1543′ placea biasing force against the bottom of pockets 1535.2′ that is in thesame direction as the axial force X applied against cutting tool 1525′during machining of an object. Thus, apparatus 1520′ is arranged andconfigured such that the normal force creating the frictional force is“self-energized” by the axial machining forces X.

Biasing elements 1543′ apply a normal force between contact surfaces1535 c′ and 1538 c′ that result in a measure of sliding frictiontherebetween that is sufficient to restrain lateral motion of toolholder 1535′ during machining, but insufficient to prevent lateralsliding of tool holder 1535′ relative to coupling element 1545′ duringadjustment. It is to be appreciated that any of the various embodimentsdescribed herein for producing this frictional force can be adapted andconfigured such that the resultant applied normal force is additive tothe axial machining forces in a “self-energizing” manner.

In a variation of this embodiment, springs 1543′ are located withinpockets of tool holder 1535′ on the opposite side of retention members1570′. For those embodiments in which coil springs 1543′ are compressionsprings, tool holder 1535′ is urged away from coupling member 1545′,with the frictional interface being between the inner surface ofretention members 1570′ and the upper, inner surface of tool member1535′. Because of the pockets being located on the opposite side ofretention members 1570′, the weight of tool holder 1535′ is reduced.Further, the length of coupling element 1545′ can be reduced, furtherreducing its weight.

FIG. 43 is a schematic representation of another embodiment according tothe present invention, shown in sectional view through the centerline ofthe apparatus. Apparatus 2320 is a boring tool assembly which includes aslidably adjustable cutting tool 2325. Cutting tool 2325 is fixedlysupported by a tool support 2330, which extends from a slidablyadjustable tool holder 2335. Preferably, apparatus 2325 further includesa coupling element 2345 which includes a coupling element body 2338, aswell as various internal components which will be described. Tool holder2335 is slidably retained on coupling member 2345, preferably by aretention member 2370. Retention member 2370 permits sliding of toolholder 2335 in a direction permitting cutting tool 2325 to bore avariety of hole diameters or other features. As one example, referringto FIG. 43, the direction is sideways.

Boring tool assembly 2320 includes an internal frictional adjustmentapparatus 2340 which includes a movable member 2344 preferably includinga surface treatment or surface coating 2347 for controlling slidingfriction and one or more biasing members 2343 which preferably providean elastic biasing force. For sake of clarity, FIG. 43 includes a singlebiasing member 2343, but it is appreciated that various embodiments ofthe present invention contemplate multiple biasing members.

Apparatus 2320 includes a pivotal boring tool which can be actuated byone or more draw bars as disclosed in PCT WO 98/48964, DE 4022579, andU.S. patent application No. 2001/0028832, all incorporated herein byreference.

Apparatus 2320 includes a pivotal tool holder 2376 a which is pivotalabout a pin 2376 b, and thereby pivotally coupled to tool holder 2335.In one embodiment, pivotal cutting tool holder 2376 a can be pivotedoutward by a mechanism (not shown) which is interposed between the topportion of the pivoting tool holder and the ramped portion of a firstdraw bar 2377 a, as described in one of the references. Draw bar 2377 ais axially actuated by a second draw bar 2377 b which is guided withincoupling element 2345. There is sufficient lateral clearance betweendraw bar 2377 b and an internal bore of tool holder 2335, such thatsliding adjustment of tool holder 2335 relative to coupling element 2345is not interfered with.

FIGS. 44-55 depicted various views of apparatus 3020 and 3120, accordingto other embodiments of the present invention. These embodiments aresimilar to the various embodiments previously described herein. However,apparatus 3020 and 3120 incorporate adjustment members which permit fineadjustment of the position of the cutting tool. Preferably, theseembodiments include an adjusting member which can be moved, by eithertranslation or rotation, from a first position to a second position byplacing a surface of the adjustment member in contact with anothermember.

For example, in one embodiment, a surface of an adjustment memberprotrudes outwardly and is spaced apart from an external surface of aboring tool. When the boring tool is coupled to a CNC boring machine,the machine can move the boring tool laterally so that the surface ofthe adjustment member comes into contact with another member. Furthermovement of the boring tool toward the member results in slidingmovement of the adjustment member. The adjustment member is coupled tothe cutting tool such that this sliding motion of the adjustment memberin a first direction results in sliding motion of the cutting tool in asecond direction. Preferably, the second direction is different than thefirst direction, although the present invention contemplates thoseembodiments in which the directions are the same.

In yet other embodiments of the present invention, the boring tool isadapted and configured such that movement of the adjustment member by afirst amount, either in a rotation or translation, results in movementof the cutting tool by a second amount, either in rotation ortranslation. Preferably, the boring tool is adapted and configured suchthat the first amount is greater than the second amount. Suchembodiments of the present invention permit fine adjustments of theposition of the cutting tool. For example, in some embodiments there isa conversion relationship between a translatable adjustment member and atranslatable cutting tool holder such that translation of the adjustmentmember by 0.001 inch results in translation of the cutting tool holderby 0.0001 inch.

FIGS. 44-48 depict various views of an apparatus 3020 according toanother embodiment of the present invention. Apparatus 3020 is a boringtool assembly which includes a slidably adjustable cutting tool 3025.Cutting tool 3025 is fixedly supported, such as by a tool support 3030,which extends from a slidably adjustable tool holder 3035. Tool holder3035 preferably includes a joint 3037 such as a dovetail joint or aT-joint which slidably couples within a complementary-shaped jointformed by pocket 3038.3 and underside surface 3070 b of retention member3070. Coupling element 3045 includes a coupling element body 3038 whichattaches to tool holder 3035, and locates boring tool assembly 3020 on adrive unit such as drive unit 3088 of machine 3082 (referring to FIG.54). Coupling element 3045 couples tool holder 3035 to the boringmachine. Coupling element 3045 is slidable in a direction relative totool holder 3035. Tool holder 3035 is adjustable over a range ofpositions in the direction for machining a hole within a range ofdimensions that correspond to the range of positions.

Boring tool 3020 preferably includes a multiple piece tool holder 3035which comprises a joint portion 3037. Referring to FIG. 46B, toolholding portion 3035.1 of tool holder 3035 includes a plurality of bores3031 a, 3031 b, and 3031 c for receiving an inserted tool support 3030.A set screw (not shown) received within the appropriate threaded hole3018 locks tool support 3030 within the specific hole.

Referring to FIGS. 46A, B, C, and D, tool holder 3035 is slidablycaptured within the assembly of coupling element 3045, as will bedescribed. Tool holder 3035 includes a plurality of spring pockets3035.5 and 3035.7. In one embodiment, each spring pocket accepts thereina biasing member 3043. As shown in FIG. 44A, in one embodiment, biasingmember 3043 is a coil spring. However, the present inventioncontemplates other types of biasing members, including, for example,pneumatically or hydraulically actuated expandable pressure vessels,coil springs, leaf springs, and belleville springs. Preferably, eachspring 3043 has a height that is greater than the depth of thecorresponding pocket 3038.1. With this arrangement, each spring will“stand proud” when placed within the corresponding pocket.

Although what has been shown and described is an arrangement in whichthe springs have an end that extends beyond the top of the correspondingpocket, the present invention also contemplates those embodiments inwhich the springs are equal in height to the pocket, or lesser inheight.

Tool holder 3035 preferably includes a scalloped recess 3071 whichslidably receives the retention edge 3072 of members 3070. A pair ofretention members 3070 are received within recess 3071 and fastened tobody 3038. Members 3070 compress the assembly of springs 3043 and jointportion 3037 of holder 3035. Fasteners 3041 are preferably tighteneduntil the underside surface 3070 b of retention 3070 is in contact withbody 1538. In one embodiment, there are eight springs 3043, and each iscompressed about 0.1 inches in this assembled condition. These eightsprings preferably provide from about 10 to 100 pounds of force perspring against body 3038.

As will be appreciated from FIG. 44A, there is a frictional interfacebetween surface 3037 b of tool holder 3035 and surface 3070 b ofretention members 3070. These facing surfaces are maintained incompression by springs 3043. Facing contact surfaces 3037 b and 3070 bare adapted and configured to provide a frictional force that issufficient to maintain tool support 3035 in place during machining, butinsufficient to prevent sliding adjustment of tool holder 3035 to a newposition, in a manner as will be described. The clamping load of thefour fasteners, the compressed springs 3043, and the frictional contactsurfaces provide a means for applying a frictional force that maintainsthe cutting tool in place during machining, but permits slidingadjustment of the cutting tool. Tightening of the four fastenersmaintains retention members 3070 in contact with surface 3037 b and theclamping surface of body 3038. However, T-joint 3037 is of a height3037.1 (refer to FIG. 46A) that is less than the corresponding depth ofpocket 3038.3 in which it is received (referring to FIG. 45A).Therefore, tightening of the four fasteners does not “bottom out”T-joint 3037 within channel 3038.3 of coupling member 3045.

The present invention contemplates application of frictional coating toeither one or both of the contact mating surfaces 3037 b and 3070 b. Inaddition to the use of a frictional material such as a brake padmaterial for a frictional coating, 3047, the present invention furthercontemplates other types of materials applied to one or more contactsurfaces, including surface coatings for increased resistance toabrasion, wear, galling, and the like. Such coatings may provide thisincreased resistance by a drop in the coefficient of friction. In suchapplications, the required frictional force can be achieved byincreasing the normal or contact force between contacting surfaces.Non-limiting examples of various surface coatings providing increasedresistance to abrasion, wear, galling, and the like include the use of aBabbitt bearing alloy, polyvinyl chloride polymer, polyethylene polymer,TFE fluorocarbon polymer, molybdenum-disulfide (with or without solidfilm lubricants such as graphite), and oil. Further, as non-limitingexamples, the present invention contemplates the use of thermochemicalcoatings, hot-dipped coatings, plating, mechanical cladding, depositedcoatings, and heat treating of the contact surfaces to achieve theappropriate wear and frictional characteristics.

Some embodiments of the present invention use one pair of contactsurfaces to provide most of the frictional force holding the tool holderstationary relative to the coupling element during machining. Othercontact surfaces placed against the tool holder can include surfacefinishes or surface coatings which have a low coefficient of friction.By limiting the high coefficient of friction coatings, materials, andsurfaces to a single pair of mating contact surfaces, the total amountand location of sliding friction applied against the tool holder can bereliably and accurately maintained.

Apparatus 3020 includes an adjustment member 3078 for effecting thesliding movement of tool holder 3035. Referring to FIGS. 47A and 47B,adjustment member 3078 includes a pair of lobes 3078 a and 3078 b.Referring to lobe 3078 b, it includes a first, a longer sliding surface3078.61 on one side, and a shorter, parallel surface 3078.62 on theother side. The remainder of the length of the second side includes anangled adjustment surface 3078.21. In one embodiment, angle 3078.8 isabout 30 degrees. However, the present invention contemplates anglesfrom about one degree to about 45 degrees. At the end of lobe 3078 b isan external contact surface 3021 used during tool position adjustment,as will be described Although lobe 3078 b has been described, similarfeatures are found on lobe 3078 a.

Referring to FIG. 45B, adjustment member 3078 fits slidably withinoffset channel 3038.5 of body 3038 of coupling 3045. Further, toolholder 3035 fits slidably within channel 3038.3 of body 3038 of coupling3045. Retention members 3070 are placed on top of tool holder 3035, andfastened onto body 3038, as best seen in FIGS. 44A and 44B. When body3038, adjustment member 3078, and tool holder 3035 are assembledtogether, the central portion of adjustment member 3078 also slideswithin channel 3035.4 of tool holder 3035. Adjustment member 3078 isable to slide in direction C and tool holder 3035 is able to slide indirection D, as referenced on FIG. 45B.

Body 3038, adjustment member 3078, and sliding tool holder 3035 areslidably coupled together and adapted and configured such that slidingmotion of adjustment member 3078 in direction C results in slidingmotion of tool holder 3035 in direction D. As one example, slidingmotion of member 3078 in a first direction results in contact of angledsurface 3078.21 with chamfered corner 3035.42 of tool holder 3035.Contact of chamfered corner 3035.42 with angled surface 3078.21 forcessurfaces 3078.61 to be in contact with walls 3038.71 of channel 3038.5.However, adjustment member 3078 is constrained to slide or translate bychannel (or slot) 3038.5. Because of the constraint to move withinchannel 3038.5, further sliding motion of adjustment member 3078increases the force applied between adjustment surfaces 3078.21 and3035.42. Since tool holder 3035 is constrained to slide within channel3038.3, continued motion of 3078 in direction C overcomes the frictionalforce between tool holder 3035 and retention members 3070, such thattool holder 3035 moves to the left in direction D (referring to FIG.45B) for upward motion of adjustment member 3078 in direction C.Likewise, downward motion in direction C of adjustment member 3078results in motion of tool member 3035 to the right in direction D (againreferring to FIG. 45B).

Boring tool 3020 is preferably adapted and figured such that channels3038.5 and 3038.3 are arranged at right angles. Angle 3078.8 ofadjustment member 3078 is chosen such that movement of member 3078 by afirst amount in direction C results in sliding motion of tool holder3035 by a second, lesser amount in direction D. Thus, motion of member3078 is converted by the angled surfaces of member 3078, the chamferedcorners of holder 3035, and the offset channels of body 3038 to areduced motion of tool holder 3035 (equivalent to a “gain” less thanone). The conversion ratio, or gain, from motion in direction C tomotion in direction D is determined by angle 3078.8. As one example,selection of angle 3078.8 as 30 degrees results in a conversion ratio ofabout 0.58 (equivalent to the tangent of angle 3078.8). Therefore,motion of adjustment member by 0.001 inches in direction C results insliding motion of tool holder 3035 in direction D by 0.00058 inches. Thegeometrical arrangement of channels 3038.5, 3038.3, and selection ofangle 3078.8 permit fine adjustment of the position of tool holder 3035.Gross movement of the adjustment member is converted to fine movement ofthe tool holder.

Tool holder 3035 includes a plurality of spring pockets 3035.7 whichcontain springs 3045 that bear against adjustment member 3078 after thefour fasteners of boring tool 3020 are tightened. These four springsprovide a frictional force that maintains adjustment member 3078 in afixed position during machining with cutting tool 3025. However, thisfrictional force is insufficient to maintain the position of adjustmentmember 3078 during adjustment of the position of cutting tool 3025.Referring to FIG. 47B, in some embodiments of the present inventionadjustment member 3078 is provided with coatings and/or surfacetreatments which control the friction between member 3078 and body 3038and member 3078 and tool holder 3035. As previously discussed herein,this frictional treatment may increase the friction at some surfaces ofmember 3078, and decrease the friction at other surfaces. Further, someembodiments contemplate hardening by coating, surface treatment, heattreating, or other method of angled surfaces 3078.21, 3078.22, as wellas chamfered corners 3035.41 and 3035.42.

Although what has been shown and described are a plurality of springs3043 which are located in pockets 3035.5 and 3035.7, it is understoodthat the present invention contemplates springs and/or biasing units ofdifferent spring constants and/or actuated normal forces of differingquantities. For example, the springs in pockets 3035.5 can have agreater spring constant than the springs used in pocket 3035.7, sincethe forces applied to the adjustment member during machining are less,in some applications, than the forces applied to tool holder 3035 duringmachining. Further, it is understood that although springs have beenshown and described, the present invention contemplates the use of anyof the force-actuating means shown and described herein, includingpneumatic, magnetic, electromagnetic, centrifugal, and other means.

FIG. 54A schematically depicts a system 3080 according to anotherembodiment of the present invention. An electronically controlledmachine (such as a CNC boring machine) 3082 uses a slidably adjustableboring tool 3020 to bore a hole 3084 in a workpiece or product 3086,such as a transmission case. Boring machine 3082 includes a drive unit3088 which releaseably couples to coupling element 3045 in aconventional manner. Drive unit 3088 provides power from a motor 3090 torotate boring tool 3020 during the boring process. In one embodiment,motor 3090 and drive unit 3088 maintain boring tool 3020 in a fixedlocation, and machining of bore 3084 is accomplished by mounting product3086 to a table 3092 which is capable of movement in multiple axes.However, the present invention also contemplates lateral and axialmovement of boring tool 3020 relative to table 3092, or lateral andaxial motions of both boring tool 3020 and table 3092. Preferably,machine 3082 includes a computer 3094 which includes memory 3095 forstoring a software algorithm 3096. Machine 3082 preferably includes aplurality of position sensors (not shown) which detect translationalmovement of table 3092 and/or drive unit 3088. Although a CNC boringmachine has been shown and described, the present invention alsocontemplates boring machines which are electronically controlled withoutthe use of a computer, as well as boring machines which are mechanicallycontrolled.

One manner of adjusting the location of cutting tool 3025 of boring tool3020 is as follows. The operator machines a feature on the object suchas a bore, measures a characteristic of the feature such as the diameterof the bore, and determines the magnitude of error in the size of thefeature. The operator then issues instructions to the CNC machine, oralternatively runs software on the CNC machine or electronicallypositions an electronically controlled boring machine or manuallypositions a manually controlled boring machine, to adjust the positionof cutting tool 3025 by a distance corresponding to the measured error.In the case of an electronically or mechanically controlled boringmachine that is not computer controlled, the operator uses theappropriate electrical or manual controls for sideways movement of theboring tool. Further, the present invention contemplates thoseembodiments in which the measurement of the diameter of the bore isperformed automatically by one or more position sensors of theelectronically controlled machine 3082. The present inventioncontemplates the use of any type of position sensor, including LVDTs,potentiometers, lasers, or any other devices known in the art.

Adjustment of the lateral position of cutting tool 3025 relative tocoupling element 3045 is accomplished by placing external surface 3021of adjustment member 3078 against a surface 3051 of a static member3050. In one embodiment of the present invention, drive unit 3088 andthe coupled boring tool are moved laterally at a first, high travel rateuntil surface 3021 is close to surface 3051, at which time a slowertravel rate is used. This placement of external surface 3021 againstrigid surface 3051 is angularly offset from the direction in which toolholder 3035 slides relative to coupling element 3045. For example, for aboring tool 3020 as shown in FIG. 251B, the rigid member 3050 extendsvertically as shown on FIG. 1B and touches the side external surface3021 of member 3078. Forces exerted between rigid member 3050 andsurface 3021 are preferably perpendicular to the direction of slidingmotion of tool holder 3035 relative to coupling element 3045. However,the present invention is not limited to the use of a vertically orientedrigid member, and contemplates any orientation for a surface thatpermits contact between the surface 3051 and an external surface 3021 ofthe adjustment member tool holder for exerting a force for slidingmovement of the tool holder 3035 relative to coupling element 3045. Insome embodiments of the present invention, the boring tool is movedrelative to a static member. In other embodiments, a member, preferablya member under control of the CNC machine, is moved relative to a staticboring tool.

As best seen in FIG. 55, surface 3051 of member 3050 is placed incontact with surface 3021 of adjustment member 3078. After the surfacescontact each other, any further movement of boring tool 3020 indirection C toward member 3050 results in sliding motion of cutting tool3052 in direction D.

This pressing together of the two surfaces does not result in slidingmovement of tool holder 3035 until the static friction force holdingtool holder 3035 in place is overcome. Once the lateral force exerted bythe machine overcomes the static frictional force, tool holder 3035moves laterally as long as the force applied by the machine is greaterthan the dynamic (or moving) frictional force applied against toolholder 3035. The machine continues to apply a lateral force untilposition sensors (not shown) of the electronic machine, or alternativelythe human operator of a manually controlled machine, indicates thatsufficient movement has occurred to place the cutting tool at the new,proper location.

Apparatus 3020 permits the operator of the CNC machine to move theboring tool 3020 by an amount that is greater than the desired movementof the cutting tool. As previously explained for the particular geometryshown and described for boring tool 3020, movement of adjustment member3078 by one unit results in movement of tool holder 3035 by 0.58 units.Inversely, if the operator intends to move the tool holder by one unit,the operator should move the adjustment member by 1.72 units (theinverse of 0.58). However, as previously explained herein, the operatorcan select movement of the adjustment member based on otherconsiderations, including consideration of “stiction”, machine wear,tool wear, and other factors known to machine operators.

Although what has been shown and described is a boring tool 3020 inwhich the adjustment member and tool holder slide at right anglesrelative to each other, the present invention is not so limited. Thepresent invention contemplates other embodiments in which boring tool3020 is adapted and configured to include an adjustment member andslidable tool holder which slide at non-perpendicular angles. Withnon-perpendicular movements of the adjusting member relative to the toolholder, it is possible to further reduce the conversion ratio (or gain)and further increase the fineness by which the position of the cuttingtool can be adjusted. As another example, selection of angle 3078.8closer to parallel with side 3078.62 or 3078.61 of member 3078 furtherincreases the fineness by which the position of the cutting tool can beadjusted. For example, for an angle 3078.8 selected as 5-6 degrees, itis possible to achieve a fineness ratio of about 10:1 (i.e., movement ofthe adjustment member by 10 units results in movement of the cuttingtool by 1 unit).

In addition, the present invention also contemplates those embodimentsin which the adjustment member is rotated rather than translated duringadjustment by the CNC machine. In these embodiments, the adjustmentmember can be linked by various gear mechanisms and/or linkages to thetool holder, such that movement of the drive unit 3088 of system 3080 bya first amount results in translation of cutting tool 3025 by a second,lesser amount. Further, as best seen in FIGS. 44A, 44B, and 54, theadjustment member and the tool holder translate in directions that aregenerally perpendicular to the rotational axis of drive unit 3088.However, the present invention also contemplates those embodiments inwhich the adjustment member is movable in a direction that is partlyorthogonal to the rotational axis, and in which movement of the toolholder is partly orthogonal to the rotational axis.

FIGS. 49-53 depict an apparatus 3120 according to another embodiment ofthe present invention. In apparatus 3120, as will be described, theinternal, angled surfaces that convert motion of the adjustment memberin a first direction to motion of a cutting tool in a second directionare provided on the cutting tool.

FIGS. 49-53 depict various views of an apparatus 3120 according toanother embodiment of the present invention. Apparatus 3120 is a boringtool assembly which includes a slidably adjustable cutting tool 3125.Cutting tool 3125 is fixedly supported, such as by a tool support 3130,which extends from a slidably adjustable tool holder 3135. Tool holder3135 preferably includes a joint 3137 such as a dovetail joint or aT-joint which slidably couples within a complementary-shaped jointformed by pocket 3138.3 and underside surface 3170 b of retention member3170. Coupling element 3145 includes a coupling element body 3138, andlocates boring tool assembly 3120 on a drive unit such as drive unit3188 of machine 3182 (referring to FIG. 54). Coupling element 3145couples tool holder 3135 to the boring machine. Coupling element 3145 isslidable in a direction relative to tool holder 3135. Tool holder 3135is adjustable over a range of positions in the direction for machining ahole within a range of dimensions that correspond to the range ofpositions.

Apparatus 3120 is the same as apparatus 3020 except as hereafter shownand described. Both apparatus 3020 and 3120 preferably include at leastone sliding member which includes a contact surface angled in adirection that is not parallel to the sliding direction of either theadjustment member or the cutting tool holder. However, the angleddirection preferably does include a directional component parallel tothe sliding direction of the adjustment member and the tool holder(i.e., the directional component is not at a right angle relative to thesliding direction). Since the direction of the angled surface is notparallel to either of the sliding directions (for instance, slidingdirections C and D as shown on FIG. 45B) and since the direction of theangled surface is not perpendicular to either sliding direction, anymovement along the angled surface is movement in both the C and Ddirections.

Preferably, either the adjustment member or the tool holder includes anangled contact surface as previously described. Since this contactsurface is located on an angle that includes directional components inboth sliding directions, movement of either the adjustment member or thetool holder results in sliding motion of the other component. Inapparatus 3020, the angled surface 3078.21 and 3078.22 are located onthe adjustment member. In apparatus 3120, the angled surfaces 3135.45are located on cutting tool holder 3135.

What has been described is the placement of an angled contact surface oneither the adjustment member or the cutting tool holder. Further,apparatus 3020 and 3120 each show a cutting tool holder that slidesorthogonally relative to the adjustment member. However, the presentinvention also contemplates those embodiments in which the cutting toolholder moves along a path that is non-perpendicular to the path of theadjustment member. Further, the present invention contemplates thoseembodiments in which both the adjustment member and the cutting toolholder include sliding surfaces that contact each other, each slidingsurface preferably being oriented at an angle that includes adirectional component in the sliding direction of the adjustment memberand a directional component in the sliding direction of the tool holder.Referring to FIG. 51, a tool holder 3135 includes a channel 3135.4 whichis adapted and configured to convert sliding motion of adjustment member3178 to sliding motion of tool holder 3135 in a different direction.Channel 3135.4 includes a pair of parallel sidewalls 3135.45. Sidewalls3135.45 are skewed at an angle 3135.8 relative to the path of adjustmentmember 3178. In one embodiment, angle 3135.8 is about 30 degrees, butthe present invention contemplates angles as low as about 1 degree up toabout 45 degrees.

Adjustment member 3178 in one embodiment includes a pair of generallyparallel sidewalls 3178.61 and 3178.62, which are guided and slidablyreceived within slot (or channel) 3138.5 (referring to FIG. 50B).Adjustment member 3178 includes a pin or projection 3178.5 which standsapart from a flat surface of member 3178. Projection 3178.5 preferablyincludes a pair of rounded sidewalls 3178.2 and 3178.4 which contactwall 3135.45 of tool holder 3135, as will be described.

Referring FIG. 50B, adjustment member 3178 fits slidably within channel3138.5 of body 3138 of coupling 3145. Tool holder 3135 fits slidablywithin channel 3138.3 of body of 3138 of coupling 3145. Retentionmembers 3170 are then placed on top of tool holder 3135 and fastened tobody 3138 as best seen in FIGS. 49A and 49B.

When body 3138, adjustment member 3178, and tool holder 3135 areassembled together, projection 3178.5 of adjustment member 3178 isslidably received within channel 3135.4 of tool holder 3135. Referringto FIG. 50B, adjustment member 3178 is able to slide in direction C andtool holder 3135 is able to slide in direction D. Body 3138, adjustmentmember 3178, and sliding tool holder 3135 are slidably coupled togetherand adapted and configured such that sliding motion of adjustment member3178 in direction C results in sliding motion of tool holder 3135 indirection D. As one example, and as best seen on FIG. 49B, projection3178.5 of adjustment member 3178 is in sliding contact with walls3135.45 of channel 3135.4. As adjustment member 3178 slides in a firstdirection, the contact surfaces 3178.2 or 3178.4 place a force againstthe corresponding channel wall 3135.45. This force between projection3178.5 and the walls of the angled channel 3135.4 couple the slidingmotion of member 3178 in a first direction into sliding motion of tool3135 in a second, different direction. For example, movement of member3178 in an upward C direction (as seen on FIG. 49B) results in movementof tool holder 3135 to the right along direction D.

Movement of projection 3178.5 within angled channel 3135.4 also places asideways force on adjustment member 3178. However, sides 3178.62 and3178.61 are preferably constrained to sliding translation between thewalls of slot 3138.5 (as best seen on FIG. 50B). Therefore, member 3178is constrained to slide in direction C when pushed or pulled duringadjustment. Because of this constraint, sliding motion of member 3178provides a force that is applied from projection 3178.5 to the walls ofchannel 3135.4 until the static friction holding tool holder 3135 isovercome. Subsequent sliding motion of member 3178 overcomes thefrictional force which is otherwise sufficient to retain tool holder3135 in place during machining operations.

Bore tool 3120 is adapted and configured such that channels 3138.5 and3138.3 are arranged at right angles. Therefore, angle 3135.8 of toolholder 3135 is chosen such that movement of adjustment member 3178 by afirst amount in direction C results in sliding motion of tool holder3135 by a second, lesser amount in direction D. Thus, body 3138, toolholder 3135, and adjustment member 3178 are adapted and configured suchthat motion of member 3178 converts to a reduced motion of tool holder3135 (equivalent to a “gain” less than one). The conversion ratio, orgain, from motion in direction C to motion in direction D is determinedby angle 3135.8. As one example, selection of angle 3135.8 as 30 degreesresults in a conversion ratio of about 0.58 (equivalent to the tangentof angle 3135.8). Therefore, motion of adjustment member 3178 by 0.001inches in direction C results in sliding motion of tool holder 3135 indirection D by 0.00058 inches. The geometrical arrangement of channels3138.5, 3138.3, and selection of angle 3135.8 permit fine adjustment ofthe position of tool holder 3135.

Apparatus 3120 permits the operator of a CNC machine to move the boringtool 3120 by an amount that is greater than the desired movement ofcutting tool 3125. Apparatus 3120 can be substituted for apparatus 3020in the system 3080, which has been previously described.

In one embodiment of the present invention, the boring tool assemblyincludes a mechanism and/or material that provides dampening of thevibratory motion. In one embodiment of the present invention, the boringtool assembly includes a first member spring-loaded into contact with asecond member. Preferably, the first and/or the second member arefabricated from a friction material, coated with a friction material,and/or coated in a manner as described previously in this application.In one embodiment, the first member is a piece of HF35 friction materialmade by Hibbing International of New Castle, Ind. This piece of frictionmaterial is in contact with a second member on one side, and on theother side is in contact with one or more biasing elements, such as coilsprings. Although the use of coil springs has been described, theinvention is not so limited, and includes any of the biasing devicesshown herein, including centrifugal, electromagnetic, hydraulic, andother means of applying a normal force.

It has been found that a boring tool assembly including a first frictionmember biased into sliding contact with a second friction member hasbeen successful in substantially reducing the chatter of a tool during amachining operation. The exact mechanisms which contribute to thereduced chatter are not fully understood. For example, it is possiblethat the first member and second member exhibit relative motion, inwhich case the dampening mechanism could be friction at the slidinginterface. Further, the friction material is known to contain someamount of rubber, which could dampen the vibratory motion by flexing ofthe rubber (thus generating internal heat). In addition, it is possiblethat the frictional interface occurs between the friction material andthe biasing mechanism (in one case, the coil springs). Yet still, it ispossible, that the placement, geometry, and stiffness of the springsresults in an internal vibrational mode which influences the otherwisevibratory motion of the boring tool assembly into vibration at a lesseramplitude.

In one embodiment, several dampening mechanisms were incorporated into aboring tool assembly in which the cutting tool was slidably adjustableas described previously. In that embodiment, the dampening mechanismalso provided static friction for holding one or more of the slidingmembers in place. During use, it was found that the tool exhibitedgreatly reduced chatter. Those of ordinary skill in the art willrecognize that the use of a dampening mechanism as described herein isnot limited to those embodiments which include slidably adjustablecutting tool holders, and is adaptable to other types of boring toolassemblies. Further, the dampening mechanism is applicable tosquared-off joints between the body and the cutting tool holder, as wellas dovetail joints and V joints.

FIGS. 56-65 depict various views of an apparatus 3220 according toanother embodiment of the present invention. Apparatus 3220 is a boringtool assembly which includes a slidably adjustable cutting tool 3225(not shown) Cutting tool 3225 is fixedly supported, such as by a toolsupport 3230 (not shown), which extends from a slidably adjustable toolholder which preferably is in two separable pieces, a retained toolholder 3235.9 and a changeable tool holder 3235.8. During adjustment ofapparatus 3220, retained tool holder 3235.9 moves laterally in responseto motion of adjustment member 3278. Changeable tool holder 3235.8 isfastened onto retained tool holder 3235.9, and moves along with it. Theuse of a two-piece, separable tool holder system permits easy change outof apparatus 3220 from one type of tool cutting apparatus to anotherkind of tool cutting apparatus, without the need to change anythingexcept changeable tool holder 3235.8. This two-piece, separable conceptpermits significant commonality of boring tool apparatuses for manydifferent types of jobs on a boring machine, thus reducing the inventorycost for the machine shop owner.

Tool holder 3235.9 preferably forms a joint 3237 such as a dovetailjoint or a T-joint which slidably couples within a complementary-shapedjoint formed by pocket 3238.3 and underside surface 3270 b of retentionmember 3270. Coupling element 3245 includes a coupling element body3238, and locates boring tool assembly 3220 on a drive unit of a boringmachine. Coupling element 3245 couples tool holder 3235.9 to the boringmachine. Coupling element 3245 is slidable in a direction relative totool holder 3235.9. Tool holder 3235.9 is adjustable over a range ofpositions in the direction for machining a hole within a range ofdimensions that correspond to the range of positions.

Apparatus 3220 is similar to other apparatuses, except as hereaftershown and described. Apparatus 2320 preferably includes at least onesliding member which includes a contact surface angled in a directionthat is not parallel to the sliding direction of either the adjustmentmember or the cutting tool holders. However, the angled directionpreferably does include a directional component parallel to the slidingdirection of the adjustment member and the tool holder (i.e., thedirectional component is not at a right angle relative to the slidingdirection). Since the direction of the angled surface is not parallel toeither of the sliding directions (sliding directions C and D) and sincethe direction of the angled surface is not perpendicular to eithersliding direction, any movement along the angled surface is movement inboth the C and D directions.

Preferably, either the adjustment member or the retained tool holderincludes an angled contact surface as previously described. Since thiscontact surface is located on an angle that includes directionalcomponents in both sliding directions, movement of either the adjustmentmember or the tool holder results in sliding motion of the othercomponent. On apparatus 3220, the angled surfaces 3235.45 are located onretained tool holder 3235.9 (as best seen in FIG. 62 c).

What has been described is the placement of an angled contact surface oneither the adjustment member or the retained cutting tool holder.Further, apparatus 3220 shows a cutting tool holder that slidesorthogonally relative to the adjustment member. However, the presentinvention also contemplates those embodiments in which the cutting toolholder moves along a path that is non-perpendicular to the path of theadjustment member. Further, the present invention contemplates thoseembodiments in which both the adjustment member and the retained cuttingtool holder include sliding surfaces that contact each other, eachsliding surface preferably being oriented at an angle that includes adirectional component in the sliding direction of the adjustment memberand a directional component in the sliding direction of the tool holder.

Adjustment member 3278 fits slidably within channel 3128.5 of body 3238of coupling 3245. Retained tool holder 3235.9 fits slidably withinchannel 3238.3 of body of 3238 of coupling 3245. Retention members 3270are then placed on top of tool holder 3235 and fastened to body 3238.

Bore tool 3220 is adapted and configured such that channels 3238.5 and3238.3 are arranged at right angles. Therefore, angle 3235.8 of toolholder 3235.9 is chosen such that movement of adjustment member 3278 bya first amount in direction C results in sliding motion of tool holder3235 by a second, lesser amount in direction D. Thus, body 3238,retained tool holder 3235.9, and adjustment member 3278 are adapted andconfigured such that motion of member 3278 converts to a reduced motionof tool holder 3235 (equivalent to a “gain” less than one). Theconversion ratio, or gain, from motion in direction C to motion indirection D is determined by application of the angular relationshipsand conversion ratios previously discussed.

Apparatus 3220 permits the operator of a CNC machine to move the boringtool 3220 by an amount that is greater than the desired movement ofcutting tool 3225. Apparatus 3220 can be substituted for apparatus 3020in the system 3080, which has been previously described.

FIGS. 66-71 depict various views of an apparatus 3320 according toanother embodiment of the present invention. Apparatus 3320 is a boringtool assembly which includes a slidably adjustable cutting tool 3325(not shown) Cutting tool 3325 is fixedly supported, such as by a toolsupport 3330 (not shown), which extends from a slidably adjustable toolholder which preferably is in two separable pieces, a retained toolholder 3335.9 and a changeable tool holder 3335.8. During adjustment ofapparatus 3320, retained tool holder 3335.9 moves laterally in responseto motion of adjustment member 3378. Changeable tool holder 3335.8 isfastened onto retained tool holder 3335.9, and moves along with it. Theuse of a two-piece, separable tool holder system permits easy change outof apparatus 3320 from one type of tool cutting apparatus to anotherkind of tool cutting apparatus, without the need to change anythingexcept changeable tool holder 3335.8. This two-piece, separable conceptpermits significant commonality of boring tool apparatuses for manydifferent types of jobs on a boring machine, thus reducing the inventorycost for the machine shop owner.

Tool holder 3335.9 preferably forms a joint 3337 such as a dovetailjoint or a T-joint which slidably couples within a complementary-shapedjoint formed by pocket 3338.3 and underside surface 3370 b of retentionmember 3370. Coupling element 3345 includes a coupling element body3338, and locates boring tool assembly 3320 on a drive unit of a boringmachine. Coupling element 3345 couples tool holder 3335.9 to the boringmachine. Coupling element 3345 is slidable in a direction relative totool holder 3335.9. Tool holder 3335.9 is adjustable over a range ofpositions in the direction for machining a hole within a range ofdimensions that correspond to the range of positions.

Apparatus 3320 is similar to other apparatuses, except as hereaftershown and described. Apparatus 3320 preferably includes at least onesliding member which includes a contact surface angled in a directionthat is not parallel to the sliding direction of either the adjustmentmember or the cutting tool holders. However, the angled directionpreferably does include a directional component parallel to the slidingdirection of the adjustment member and the tool holder (i.e., thedirectional component is not at a right angle relative to the slidingdirection). Since the direction of the angled surface is not parallel toeither of the sliding directions (sliding directions C and D) and sincethe direction of the angled surface is not perpendicular to eithersliding direction, any movement along the angled surface is movement inboth the C and D directions.

Preferably, either the adjustment member or the retained tool holderincludes an angled contact surface as previously described. Since thiscontact surface is located on an angle that includes directionalcomponents in both sliding directions, movement of either the adjustmentmember or the tool holder results in sliding motion of the othercomponent. In apparatus 3320, the angled surfaces 3335.45 are locatedwithin a slot 3335.4 that is defined within adjusting member 3378 (asbest seen in FIG. 68 b).

What has been described is the placement of an angled contact surface oneither the adjustment member or the retained cutting tool holder.Further, apparatus 3320 shows a cutting tool holder that slidesorthogonally relative to the adjustment member. However, the presentinvention also contemplates those embodiments in which the cutting toolholder moves along a path that is non-perpendicular to the path of theadjustment member. Further, the present invention contemplates thoseembodiments in which both the adjustment member and the retained cuttingtool holder include sliding surfaces that contact each other, eachsliding surface preferably being oriented at an angle that includes adirectional component in the sliding direction of the adjustment memberand a directional component in the sliding direction of the tool holder.

Adjustment member 3378 fits slidably within channel 3328.5 of body 3338of coupling 3345. Retained tool holder 3335.9 fits slidably withinchannel 3338.3 of body of 3338 of coupling 3345. Retention members 3370are then placed on top of tool holder 3335 and fastened to body 3338.

Boring tool 3320 is adapted and configured such that channels 3338.5 and3338.3 are arranged at right angles. Therefore, angle 3335.8 of toolholder 3335.9 is chosen such that movement of adjustment member 3378 bya first amount in direction C results in sliding motion of tool holder3335 by a second, lesser amount in direction D. Thus, body 3338,retained tool holder 3335.9, and adjustment member 3378 are adapted andconfigured such that motion of member 3378 converts to a reduced motionof tool holder 3335 (equivalent to a “gain” less than one). Theconversion ratio, or gain, from motion in direction C to motion indirection D is determined by application of the angular relationshipsand conversion ratios previously discussed.

Apparatus 3320 permits the operator of a CNC machine to move the boringtool 3320 by an amount that is greater than the desired movement ofcutting tool 3325. Apparatus 3320 can be substituted for apparatus 3020in the system 3080, which has been previously described.

FIGS. 72-78 depict various views of an apparatus 3420 according toanother embodiment of the present invention. Apparatus 3420 is a boringtool assembly which includes a slidably adjustable cutting tool 3425(not shown) Cutting tool 3425 is fixedly supported, such as by a toolsupport 3430 (not shown), which extends from a slidably adjustable toolholder which preferably is in two separable pieces, a retained toolholder 3435.9 and a changeable tool holder 3435.8. During adjustment ofapparatus 3420, retained tool holder 3435.9 moves laterally in responseto motion of adjustment member 3478. Changeable tool holder 3435.8 isfastened onto retained tool holder 3435.9, and moves along with it. Theuse of a two-piece, separable tool holder system permits easy change outof apparatus 3420 from one type of tool cutting apparatus to anotherkind of tool cutting apparatus, without the need to change anythingexcept changeable tool holder 3435.8. This two-piece, separable conceptpermits significant commonality of boring tool apparatuses for manydifferent types of jobs on a boring machine, thus reducing the inventorycost for the machine shop owner.

Tool holder 3435.9 preferably forms a joint 3437 such as a dovetailjoint or a T-joint which slidably couples within a complementary-shapedjoint formed by pocket 3438.3 and underside surface 3470 b of retentionmember 3470. Coupling element 3445 includes a coupling element body3238, and locates boring tool assembly 3220 on a drive unit of a boringmachine. Coupling element 3445 couples tool holder 3435.9 to the boringmachine. Coupling element 3445 is slidable in a direction relative totool holder 3435.9. Tool holder 3435.9 is adjustable over a range ofpositions in the direction for machining a hole within a range ofdimensions that correspond to the range of positions.

Apparatus 3420 is similar to other apparatuses, except as hereaftershown and described. Apparatus 3420 preferably includes at least onesliding member which includes a contact surface angled in a directionthat is not parallel to the sliding direction of either the adjustmentmember or the cutting tool holders. However, the angled directionpreferably does include a directional component parallel to the slidingdirection of the adjustment member and the tool holder (i.e., thedirectional component is not at a right angle relative to the slidingdirection). Since the direction of the angled surface is not parallel toeither of the sliding directions (sliding directions C and D) and sincethe direction of the angled surface is not perpendicular to eithersliding direction, any movement along the angled surface is movement inboth the C and D directions.

Preferably, either the adjustment member or the retained tool holderincludes an angled contact surface as previously described. Since thiscontact surface is located on an angle that includes directionalcomponents in both sliding directions, movement of either the adjustmentmember or the tool holder results in sliding motion of the othercomponent. In apparatus 3420, the angled surfaces 3435.4 are locatedwithin either of a pair of slots defined within adjustment member 3478.

What has been described is the placement of an angled contact surface oneither the adjustment member or the retained cutting tool holder.Further, apparatus 3420 shows a cutting tool holder that slidesorthogonally relative to the adjustment member. However, the presentinvention also contemplates those embodiments in which the cutting toolholder moves along a path that is non-perpendicular to the path of theadjustment member. Further, the present invention contemplates thoseembodiments in which both the adjustment member and the retained cuttingtool holder include sliding surfaces that contact each other, eachsliding surface preferably being oriented at an angle that includes adirectional component in the sliding direction of the adjustment memberand a directional component in the sliding direction of the tool holder.

Adjustment member 3478 fits slidably within channel 3428.5 of body 3438of coupling 3445. Retained tool holder 3435.9 fits slidably withinchannel 3438.3 of body of 3438 of coupling 3445. Retention members 3470are then placed on top of tool holder 3435 and fastened to body 3438.

Bore tool 3420 is adapted and configured such that channels 3438.5 and3438.3 are arranged at right angles. Therefore, angle 3435.8 of toolholder 3435.9 is chosen such that movement of adjustment member 3478 bya first amount in direction C results in sliding motion of tool holder3435 by a second, lesser amount in direction D. Thus, body 3438,retained tool holder 3435.9, and adjustment member 3478 are adapted andconfigured such that motion of member 3478 converts to a reduced motionof tool holder 3435 (equivalent to a “gain” less than one). Theconversion ratio, or gain, from motion in direction C to motion indirection D is determined by application of the angular relationshipsand conversion ratios previously discussed.

Apparatus 3420 permits the operator of a CNC machine to move the boringtool 3420 by an amount that is greater than the desired movement ofcutting tool 3425. Apparatus 3420 can be substituted for apparatus 3020in the system 3080, which has been previously described.

FIGS. 56-79 depict various other embodiments according to the presentinvention. Several of these figures are scaled: FIGS. 60 a, 60 b, 60 c,61 (all), 62 (all), 64 (all), 65 (all), 66 (all), 67 (all), 68 (all), 69(all), 70 (all), 71 (all), 74 (all), 75 a, 75 b, 76 (all), 77 (all), and78. These scaled drawings also include many dimensions, all expressed ininches. The dimensions are recognizable apart from the element numbers,since the dimensions generally include one or more arrows that extend tolead lines that are aligned with various features of the particularapparatus.

Referring to FIG. 58, the boring tool apparatus 3220 is shown with theretention members and changeable tool holder removed. Adjustment member3278 slidingly fits within a channel of body 3138. Projection or tang3278.5 is slidingly received within slot 3235.4 of retained tool holder3235.9. Movement of adjustment member 3278 in a first direction Cresults in sliding movement of retained tool holder 3235.9 in adirection D that is at least partly orthogonal to direction C. Asprojection 3278.5 moves in direction C, a side surface of projection3278.5 pushes in direction C upon a wall of channel of 3235.4. Becauseof the angular geometry previously discussed, tool holder 3235.9 slidesin direction D.

FIG. 59 is a side elevational view of apparatus 3220 with tool holders3235.8 and 3235.9 extended to the left so as to show internal componentsof the retained tool holder. A brake member 3244.6 (with surface shownin crosshatch) is retained within a pocket 3235.91 which is milled intoa face of retained tool holder 3235.9 (which can also be seen in FIG. 62d). A plurality of coil springs (not shown) reside within individualpockets 3238.1 and urge brake member 3244.6 laterally against a surfaceL of body 3238, as best seen in FIG. 60 b. Preferably, springs and brakemembers are placed on opposing sides of retained tool holder 3235.9, andpress outward against both walls L of body 3238. In one embodiment, eachspring is a coil spring. In one particular embodiment, the springs wereFastenall ⅝ by 1-inch gold springs, Part No. 300450. In yet anotherparticular embodiment, the springs were Fastenall ⅝ by 1-inch redsprings, Part No. 300353. However, those of ordinary skill willrecognize that the biasing of brake member 3244.6 can be accomplished byany of the biasing methods and apparatus described herein. In someembodiments of the present invention, it is believed that the springsand brake member contribute to dampening of vibratory motion that wouldotherwise be manifested as tool chatter.

Referring to FIG. 60 c, body 3238 preferably defines a plurality ofspring pockets M and a generally rectangular brake pad pocket 3238.5. Acoil spring or other biasing member presses against a surface of body3238, and urges a brake pad 3244.5 against the underside of theunderside N of adjustment member 3278 (as best seen in FIG. 61 a). Thebiasing apparatus, such as coil springs, place a force on brake member3244.5 which results in a frictional force to retain adjustment member3278 in a particular location. Thus, boring tool apparatus 3220 includesfrictional and/or damping mechanisms to retain both the adjustmentmember 3278 and the retained tool holder 3235.9 in location. Referringto FIG. 59, placement of the brake member 3244.6 so as to applyfrictional loads laterally to the centerline of boring tool 3220 resultsin an overall reduction in the length of boring tool 3220. Thisreduction in length further decreases the likelihood of tool chatter byreducing the weight of apparatus 3220. Referring to FIG. 65 b,changeable tool holder 3235.8 includes a pilot A1 projecting from a pairof pilots A1 projecting from the bottom thereof. Pilots A1 are receivedwithin bores B1 of tool holder 3235.9, as best seen in FIG. 62 c. A setscrew received within a perpendicular tapped hole provides a compressionforce to hold the changeable tool holder firmly within the retained toolholder. Referring to FIGS. 66 a and 66 b, a changeable tool holder3335.8 includes a pair of counterbored through slots. A fastenerreceived within each of the slots clamps changeable tool holder 3335.8to a retained tool holder 3335.9. Retained tool holder 3335.9 furtherincludes a lengthwise channel B 1 (as best seen in FIG. 69 c) thatslidingly receives rectangular projection A1 of changeable tool holder3335.8 (as best seen in FIG. 71 b). Tool holder 3335.9 includes aprojection 3378.5 (FIG. 69 b) that is slidingly received within slot3335.4 of adjustment member 3378 (FIG. 68 b). Referring again to FIG. 69b, retained tool holder 3335.9 defines a pair of pockets M which areadapted and configured to receive therein a generally rectangular pieceof friction material 44, as previously described. One or more coilsprings located within a pocket 3338.1 urge the brake member (not shown)against a first surface of N of adjustment member 3378 (FIG. 68 a). Athird separable brake member (not shown) is retained within pocket3338.1B of body 3338 (as best seen in FIG. 67 c). This third brakemember is urged by one or more biasing members, such as coil springswithin pockets 3338.1, against surface O of adjustment 3378 (FIG. 78 a).Thus, adjustment member 3378 is “sandwiched” between frictional brakemembers that are biased so as to compress adjustment member 3378.

FIGS. 72 a and 72 b are front and side views, respectively, of anapparatus 3420 according to another embodiment of the present invention.In both of these views retaining members 3470 have been removed. Whenretaining members 3470 are in place, surface P and surface Q are atapproximately the same height. With the members removed, it is possibleto better see the brake members within apparatus 3420. Referring to FIG.72 a, the inner edges of two brake members 3444 can be seen between thetop surface of adjustment member 3478 and the bottom surfaces of toolholders 3435 a and 3435 b. Another brake member 3444.6 can be seen incontact with the underside of adjustment member 3478. Biasing memberssuch as coil springs urge brake members 3444 into frictional contactwith the top surface of 3478. Additional biasing members, such as coilsprings located within pockets of body 3438, urge brake member 3444.6into frictional contact against 3478. Adjustment member 3478 is“sandwiched” between these frictional members. Brake member 3444.6 fitswithin pocket 3438 p (FIG. 74 c). A brake member 3444 fits withinpockets 3435P of tool holders 3435 a and 3435 b (FIGS. 77 a and 78 a).

Referring to FIG. 73 b, it can be seen that projections 3478.5 a and3478.5 b (FIGS. 77 c and 78 c) are slidingly received withincorresponding channels 3435.4 of adjustment member 3478 (FIG. 75 b).Referring to FIGS. 60 b and 60 c, frictional or damping mechanisms thusact between tool holder 3235.9 and surface L of body 3238. Separatefrictional forces are applied by brake members 3244.5 within pockets Magainst adjusting member 3278. Thus, both the tool holder and adjustingmember are separately dampened. Referring to FIG. 79, some embodimentsof the present invention include a body 3538 which has on it a pluralityof grooves R on a surface Q. Surface Q is in sliding contact with abiased brake member. Grooves R assist in channeling away any lubricatingfluid and/or cutting fluid that is used in the machining operation.Grooves R thus act similar to rain grooves in an automobile tire.Although grooves R are shown on a surface of a body 3538, the presentinvention contemplates the use of grooves at any of the frictionalinterfaces, where a brake member is in contact with another member.Further, although a semicircular pattern of grooves is shown, anypattern of closely spaced grooves is contemplated by the presentinvention. In one embodiment, these grooves have a radius ofapproximately 0.030 inches, and are approximately 0.030 inches deep.

Other embodiments of the present invention pertain to the use of atwo-piece, separable tool holder. A first, changeable tool holder isfastened (such as by bolts) to a retained tool holder. The retained toolholder is adjustable in the manner described herein in the variousembodiments by application of a force against a moving member of theboring tool apparatus. For example, the force can be placed directlyagainst the retained tool holder, or can be placed against an adjustmentmember which is in sliding contact with the retained tool holder.Further, the embodiments including two-piece, separable tool holders arenot limited to slidingly adjustable tool holders according toembodiments of the present invention, but are also applicable toconventional boring tool apparatus.

The retained slidable tool holder is adapted and configured to be insliding contact with another component of the boring tool. Thechangeable tool holder is provided with a relatively simple interfaceand fastens to the retained tool holder. In this way, a variety ofdifferent changeable tool holders can be used with the same retainedtool holder, thus decreasing the expensive tool inventory in a machineshop.

Yet other embodiments of the present invention pertain to the use ofdampening in a boring tool assembly to reduce tool chatter. Those ofordinary skill in the art recognize that tool chatter is a timeconsuming, expensive, and damaging phenomenon in the area of machining.Tool chatter occurs when the cutting tool exhibits vibratory motionduring machining. In some cases the chatter is a response initiated bycontact of the cutting tool with the workpiece which results invibratory motion of the cutting tool, the cutting tool holder, and othercomponents of the boring tool assembly. This vibratory motion can be aresult of bending or flexing of one or more components of the boringtool assembly, and can also be relative movement between two adjacentcomponents of the boring tool assembly.

While the invention has been illustrated and described in detail in thedrawings and foregoing description, the same is to be considered asillustrative and not restrictive in character, it being understood thatonly the preferred embodiments have been shown and described and thatall changes and modifications that come within the spirit of theinvention are desired to be protected.

1. A system for boring a hole, comprising: a computer numericallycontrolled machining apparatus having a rotating drive member rotatableabout an axis; a member with a first surface, the member being proximatesaid machining apparatus; a boring tool including a coupling member forcoupling said boring tool to said drive member, a cutting tool holderslidably coupled to said boring tool, and a slidable adjustment memberslidably coupled to said boring tool, said adjustment member having asecond surface; and an electronic controller operably coupled to saidmachine, said controller performing an algorithm which adjusts thesliding position of said cutting tool holder by placing the firstsurface in contact with the second surface and applying a forcethereacross.
 2. The system of claim 1 wherein the second surface of saidadjustment member is spaced apart from and external to the outer surfaceof said boring tool, and application of the force pushes the secondsurface in a direction toward said boring tool.
 3. The system of claim 1wherein the second surface of said adjustment member is spaced apartfrom and external to the outer surface of said boring tool, andapplication of the force pulls the second surface in a direction awayfrom said boring tool.
 4. The system of claim 1 wherein said machiningapparatus is a boring machine
 5. The system of claim 1 wherein saidelectronic controller is a computer with a memory and said algorithm isa software program.
 6. A method comprising: providing an object, a CNCboring machine, and a boring tool including a cutting tool slidablewithin a first range of positions and an adjusting member slidablewithin a second range of positions; machining a feature in the object bythe CNC boring machine with the boring tool; determining a first amountto adjust the position of the cutting tool holder within the firstrange; and adjusting the position of the cutting tool with the aid ofthe CNC boring machine by sliding the adjusting member within the secondrange by a second amount greater than the first amount.
 7. The method ofclaim 6 wherein the second range is greater than the first range.
 8. Themethod of claim 6 wherein the movement in the first range is linearlyrelated to movement in the second range.
 9. A method comprising:providing an object, a CNC boring machine, and a boring tool including acutting tool slidable in a first direction and an adjusting memberslidable in a second direction different than the first direction;machining a feature in the object by the CNC boring machine with theboring tool; determining a first amount to adjust the position of thecutting tool in the first direction; and adjusting the position of thecutting tool in the first direction with the aid of the CNC boringmachine by sliding the adjusting member in the second direction.
 10. Themethod of claim 9 wherein the second direction is not parallel to thefirst direction.
 11. The method of claim 9 which further comprisescoupling movement of the adjusting member in the second direction tocause movement of the cutting tool in the first direction.
 12. Themethod of claim 9 which further comprises converting a greater amount ofmotion of the adjusting member in the second direction to a lesseramount of motion of the cutting tool in the first direction.
 13. Amethod for adjusting the position of a cutting tool holder for boringholes, comprising: providing a boring tool having a rotational axis andincluding a cutting tool holder slidable in a first direction and anadjustment member, the adjustment member being slidable in a seconddirection at least partly orthogonal to the rotational axis; sliding theadjustment member in the second direction; coupling the movement of theadjustment member to the movement of the cutting tool holder; slidingthe cutting tool holder in the first direction by said sliding theadjustment member.
 14. The method of claim 13 wherein the seconddirection is different than the first direction.
 15. The method of claim13 wherein the second direction is generally perpendicular to therotational axis.
 16. The method of claim 13 wherein said couplingincludes a surface of the adjustment member being in contact with asurface of the cutting tool holder.
 17. The method of claim 13 whereinthe second direction is generally perpendicular to the rotational axisand the first direction is generally perpendicular to the rotationalaxis.
 18. The method of claim 17 wherein first direction is generallyperpendicular to the second direction.
 19. An apparatus for machining afeature with a boring machine, comprising: an adjustable position toolholder for holding a cutting tool; a slidable adjustment member foradjusting the position of said tool holder and slidably coupled to saidtool holder; a coupling element for coupling the tool holder to theboring machine, said tool holder and said adjusting member beingslidably coupled to said coupling element; wherein said coupling elementis adapted and configured to rotate about an axis, said tool holder isslidable relative to said coupling element in a first direction at leastpartly orthogonal to the axis, said adjustment member is slidablerelative to said coupling element in a second direction different thanthe first direction, and said tool holder is adapted and configured toslide in the first direction in response to sliding of said adjustmentmember in the second direction.
 20. The apparatus of claim 19 whereincoupling member includes a first channel which slidably receives saidtool holder and a second channel which slidably receives said adjustmentmember.
 21. The apparatus of claim 19 which further comprises aplurality of springs for providing a frictional force between said toolholder and said coupling element.
 22. The apparatus of claim 19 whereinthe second direction is at least partly orthogonal to the firstdirection.
 23. The apparatus of claim 19 wherein one of said adjustmentmember or said tool holder includes a first linear adjustment surfaceadapted and configured for sliding contact with a second adjustmentsurface of the other of said adjustment member or said tool holder, andthe first adjustment surface is arranged at an angle which includes adirectional component of the first direction and a directional componentof the second direction.
 24. An apparatus for machining a feature with aboring machine, comprising: an adjustable position tool holder forholding a cutting tool; a coupling element for coupling the tool holderto the boring machine, said tool holder being slidable relative to saidcoupling element in a first direction; a slidable adjustment memberslidably coupled to said coupling element and slidable in a seconddirection different than the first direction; wherein said tool holder,said coupling element, and said adjustment member are adapted andconfigured such that said tool holder slides in the first direction inresponse to sliding of said adjustment member in the second direction,and said tool holder slides by a first amount in response to sliding ofsaid adjustment member by a second amount, the first amount being lessthan the second amount.
 25. The apparatus of claim 24 wherein thesliding motion of said adjustment member is translation and the slidingmotion of said tool holder is translation.
 26. The apparatus of claim 24wherein the ratio of the second amount to the first amount is greaterthan about two to one.
 27. The apparatus of claim 24 wherein said toolholder and said adjustment member are in sliding contact along a surfacethat is non-parallel to the first direction and non-parallel to thesecond direction.
 28. A method for reducing tool chatter, comprising:providing a boring tool assembly including a body adapted and configuredto be driven by a boring machine, a cutting tool holder adapted andconfigured to be retained by the body, and a cutting tool adapted andconfigured to be held by the cutting tool holder, and a separable memberand a spring; biasing the separable member against one of the body orthe cutting tool holder by the spring; and placing the other end of thespring in contact with the other of the body for the cutting toolholder.
 29. An apparatus for boring a hole, comprising: a tool bodyhaving a first channel and a second channel, said first and secondchannels being nonparallel; a first sliding member slidingly receivedwithin the channel of said body; a second slidable member slidablyreceived within the second channel of said body; a slot defined withinone of the first member or second member; a projection extending from asurface of the other of the first member or the second member, saidprojection being received within the slot; wherein sliding motion of thefirst member in the first channel results in sliding motion of thesecond member within the second channel.
 30. The apparatus of claim 29which further comprises a first frictional member urged against asurface of said first member, and a second frictional member urgedagainst a surface of said second member.
 31. The apparatus of claim 30which further comprises a cutting tool, wherein said cutting tool isattached to said first member.
 32. The method of claim 1 wherein saidcomputer numerically controlled machining apparatus includes atranslatable table and said drive member is a translatable, and whereinthe force is applied by translating one of said table and said drivemember relative to the other of said table and said drive member. 33.The method of claim 6 wherein the adjusting member is linearly slidablewithin the second range of positions and is slidably coupled to theboring tool.
 34. The method of claim 33 wherein the cutting tool islinearly slidable within the first range of positions.
 35. The method ofclaim 6 wherein the CNC boring machine includes a translatable drivingelement for driving the boring tool and a translatable table, andwherein said adjusting is by moving one of the table or the drivingelement relative to the other by the second amount.
 36. The method ofclaim 9 wherein the second direction is generally perpendicular to therotational axis of the boring tool.
 37. The system of claim 9 whereinthe adjustment member includes an external surface, and said sliding ofthe adjustment member is by pushing the external surface.
 38. The systemof claim 9 wherein the adjustment member includes an external surface,and said sliding of the adjustment member is by pulling the externalsurface.
 39. The method of claim 9 wherein the CNC boring machineincludes a translatable table and a translatable drive member fordriving the boring tool, and wherein the force is applied by translatingone of said table and said drive member relative to the other of saidtable and said drive member.
 40. The method of claim 13 wherein saidsliding the adjustment member is by applying an external force to theadjustment member.
 41. The apparatus of claim 19 wherein the seconddirection is at least partly orthogonal to the axis.
 42. The apparatusof claim 24 wherein said coupling element is rotatable about an axis,and the second direction is not parallel to the axis.
 43. The system ofclaim 24 wherein said slidable adjustment member includes an externalsurface, and the sliding of said adjustment member is by pushing theexternal surface.
 44. The system of claim 24 wherein said slidableadjustment member includes an external surface, and the sliding of saidadjustment member is by pulling the external surface.
 45. The apparatusof claim 29 wherein said tool body is rotatable about an axis, and thefirst channel is not parallel to the axis, and second channel is notparallel to the axis.